So I damaged the stator cover case on my 07 today practicing wheelies. I'm JB welding it for now.
Does anyone know if the 09+ cover(PN 14031-0110) will fit on the 06/07 bikes(PN 10431-0042)?

edit: I'm seeing the cover gasket is the same part number, so the covers must be the same.

 

I think it's just a different color but I don't know how to validate that.

 

The gasket used for the cover has been the same for all the electric starts and I think even some others, including 300s. So the 09 cover should fit case to case, I doubt the over all shape has changed since it's simply the stator cover and I doubt the stator has been re-engineered in the past 20 years. It has to be the electric start cover though. And again the gasket shows the cover fits every electric start 250 from 06-20. The number change for the cover is very likely because of the finish on the cover, not the actual shape of the cover.

but I'd still see if I could find a good TIG welder and have them weld it up. Someone who can make a fine bead. Takes a seriously good welder because of the small part, no big gobby welds that affect the fit. I will also say I think the JB Weld may work, but kind of risky if inside should it peel.

 

I think you are right. The only difference(aside from colour) seems to be that the 06/07 cover has "Kawasaki" embosed on it, and the newer ones are smooth.

I tried to JB weld it for the time being but it seems to be leaking unfortunately. I cleaned the whole part, sanded it, and used JB weld original on both sides. Let it cure for 24 hours(at 28C), and no dice.

 

Read up on a product called Quiksteel, it sets up in oil so after a trail side repair it will cure while you ride

 

TIG weld it. Go to a local bike shop and ask if they know anyone who can do fine TIG welding. A friend of mine has done a number of jobs doing fine TIG welding, like welding up broken cases on a motocross bike, welding pontoons on a pontoon boat, and welded up a custom high pipe for my SR500. Find someone like that.