Case saver
 

Sometimes you gotta run with it when the inspiration hits you. I made this up Saturday afternoon after getting the bug. This is my second try at a case saver. I ended up not liking the first one I made a couple years ago.

Running the stock cover in many of the heavy clay mud places I ride. The mud gets jammed in there, and starts coming out the holes in the plastic cover like play-doh.

First version is laying on the left. Cardboard template for the new one. Worn out diamond grinding wheel provides the raw aluminum stock. :D TNC will call me cheap again.

Attachment 10881

Bandsaw cut out.
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Beltsander cleans up the saw cut.
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Bandsaw again for the notch. Files to clean up the cut to an even thickness (within .005).
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My handy $400+ "extra crankcase" for easy fit checks.
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A little wet sanding
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A little polish. ( I may take it back to the sanded finish, not sure which I like best. )
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On the bike.
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Dan

Pictures of my first one. I don't like the pinch point this one creates. You could really get a rock jammed in there.

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The prototype I made has taken a few hits.
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https://www.kawasakiforums.com/forum...-models-38813/

Attachment 10880

Cheap or not, dan, that's some nice work there. It's looks effective, well contoured for the application, and super strong. Good stuff.

Nice work, Dan.

Nice work Dan; you probably saved ~$50 compared to some of the fancy CNC anodized case savers I have seen.
In the few instances I have seen chains come off, damage has ranged from nothing to catastrophic. I know it's pretty unpredictable to know what a broken chain is going to do once it's loose, but the common denominator in the instances I saw with no damage was the presence of a case saver. I wouldn't ride without one.

What's the white thing you have stuck to the engine case? Looks kind of like the DRZ engine covers.

That there is some nice work. What size front sprocket is that?

i like that sketch too!

EMS, it says 14T on his drawing.

Thanks guys. We'll see how it works out. I'm thinking the leading edge of it will take a bit of a beating from the chain and whatever else gets drug in there.
The sprocket on the bike is a 14t.
Mike the thing on the stator cover is a guard I made up.https://www.kawasakiforums.com/forum...otector-39780/ Probably similar to the drz one you mention. One of my buddies has something like that on his KTM. The used stator cover I got off eBay to replace mine had a good gouge in it, so this will give me a little extra insurance.
Dan

How much and when can we expect delivery. :)

Whats the round plate in this picture? Did I miss the writeup on that one? Interesting.

Attachment 10873

Stator cover guard.

You need to stop by more often, Deej.

Come back to KLX land.

Fine looking workmanship. Wish there was at least *ONE* person who worked on building my new house that had that kind of attention to detail and work ethic...

So, when are you starting production on them?

I want to run it for a bit and see if there are any bugs. I really don't have a great way to mass produce them either. I do have one idea that might work out, but I will have to look into it more. I could make each one by hand but I don't think you guys want to pay $80 a piece for them :D . I'll keep you posted.
Dan

There are plenty of CNC shops out there that could make up a few dozen for fairly cheap. Most shops like a 3D CAD file to program to. I can help you with that if need be.

Case saver
 

Nice work. I would take one if they were available.:)

Thanks for the offer Cmott. I work for a big place that used to let you do govt. work like this. One off stuff at least. I want to see how this prototype work, then go from there. I have a su****ion that it might need to be opened up some in a couple places.
Dan

edit KF Automatically covers the letters s,p,i,c in susp icion ^^^ LOL

Hey Dan, Nice work. If you need a test monkey, I'd be happy to try one out.

Put 30 hard miles on the rebuilt engine, and the prototype case saver. As I suspected, the chain is flinging off on deceleration and rubbing the case saver. I'll open it up some and try again. :D Happy to report that the engine/trans had no issues.
FYI I'm looking into having a number of them water-jet cut.
Dan

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I know that the step is on the wrong side in this one :D
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Dan, that case saver is so tiny and fragile that I doubt you have any ability to take off any material for the chain contact without the thing turning to dust.:D

It's not like TNC to do this, but I think he is being sarcastic here. If it is sarcasm, by the definition of the word, he is telling me that my case saver is big and robust, maybe overly so, and could/should be pared down. My reply here is to my version of what he meant to say. I really don't want to go too much thinner in the area directly in front of the sprocket. I'm going to, but I'd rather not. The big lead in can be opened up without a problem.
:D Dan

Dan, you get an "A" for comprehensive reading:D

But seriously, that's a nice, robust looking design, and I can't imagine that you'd do much to weaken the function of the guard to any real degree. I totally agree on the upper, "lead-in" portion of the guard, as it does seem a little close. I'm guessing you don't want to create too much space, so as not to give the chain a chance to wad up in the extra space if some disaster occurs, but that constant contact with metal, even aluminum, is vibratory in nature which is probably not good for the pins and rollers. It gets enough already from the sprockets. Still, probably all much ado about nothing. I'm a little amazed at how much a top drawer chain gets its contact points flattened a little just from rubbing on the chainguides, skid blocks, and rollers. My Hotfoot Moto guides have little signs of any wear, but the chain has definitely gotten its rounded edges flattened a tiny bit...and only one chain adjustment in thousands of miles.

any updates on this?

Interesting. I considered doing something like that, but not quite that heavy duty. I wouldn't worry about the grooving though. Once deep enough the rollers will hit and roll. No big deal and far better than chain on the case. I was thinking get it centered on the rollers using spacers, avoiding mill work as another cost savings..

Have to consider putting this on the summer to-do list.

hence me bring this back....

I will see what can be done.

I have the stock guard back on there now. I got a Husqvarna TE 250 a few years ago, and the KLX was relegated to mostly street riding. Switched it because I was worried about catching a pant leg in the open design of the one i detailed in this thread. I'll look in my parts drawer and post up about the condition of the one in this thread.
Dan

Dan, no problem with you if I play with the guard? I don't want to step on toes.

classy! i like the sportsmanship

Well sorry to say that i cant even locate the guard i made up. Its around but....Have at it Mark, and thanks for asking. :) . Sorry I couldn't give you more feedback on the original.
Dan

I wanted to do so with my KLX650 and with the 250. If it works I'd get some made up if cost effective. At least I have the bikes to do it. I have a WR250 rider that wants me to try to make a metal swing arm guard, because they tend to saw through the swing arm. It would be great to do one that would fit under the plastic slider. Problem - I don't have a bike or swing arm to do the work. Bummer. it's fun to make stuff and see if it can do the job.

I just bought a set of case covers for a drz 400 off amazon for 26.00, gonna how good i can get them to fit on the klx

Cool.
Keep us apprised.

im still healing from the wipe out 3 weeks ago, ankle and ribs are still pretty tender. This and a few other winter projects planned since im keeping the bike in the garage to work on over the winter

So these just came in today from german.....according to my measurements the left side should need very little trimming to fit. However the right side is going to need a relief cut for the clutch actuator