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04-05 TRX 450R RIGHT SIDE CASE LEAK

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13K views 13 replies 10 participants last post by  Theviking  
#1 ·
Anyone out there have an 04-05 TRX 450r with a tranny leak behind the kick where the retaining clip for the brake wire is held under the 8mm head? I found one on mine and can't believe a Honda would do that. It looks like a hair line crack where the case meets the radial point for the bolt. When riding it looks like a lot leaks out, even making it back to the axle... I got home from a dune weekend in Glamis and found that it only lost about an ounce after draining it into a ratio right. I tried a couple of rigged fixes like silicoln and jb weld with no success. Also pricing the parts it's about 200 to get the case, gaskets, bearings and seals to replace it. Not really what I want to do during dez season...
Any suggestions?????
 
#2 ·
Anyone out there have an 04-05 TRX 450r with a tranny leak behind the kick where the retaining clip for the brake wire is held under the 8mm head? I found one on mine and can't believe a Honda would do that. It looks like a hair line crack where the case meets the radial point for the bolt. When riding it looks like a lot leaks out, even making it back to the axle... I got home from a dune weekend in Glamis and found that it only lost about an ounce after draining it into a ratio right. I tried a couple of rigged fixes like silicoln and jb weld with no success. Also pricing the parts it's about 200 to get the case, gaskets, bearings and seals to replace it. Not really what I want to do during dez season...
Any suggestions?????[/b]
Click to expand...

my was leaking last year, turns out i had a cracked innner clutch cover, good news is they sell on ebay all the time for around 50-60 bucks, and they are not hard to replace, bad news is there is no fixing that one you have to et a new one, they sell new for 130, but thats what your problem is


its cause by pressure from the kickstart mine split right beind the bolt hole you will see what i mean when you take it off
 
#3 ·
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Anyone out there have an 04-05 TRX 450r with a tranny leak behind the kick where the retaining clip for the brake wire is held under the 8mm head? I found one on mine and can't believe a Honda would do that. It looks like a hair line crack where the case meets the radial point for the bolt. When riding it looks like a lot leaks out, even making it back to the axle... I got home from a dune weekend in Glamis and found that it only lost about an ounce after draining it into a ratio right. I tried a couple of rigged fixes like silicoln and jb weld with no success. Also pricing the parts it's about 200 to get the case, gaskets, bearings and seals to replace it. Not really what I want to do during dez season...
Any suggestions?????[/b]
Click to expand...

my was leaking last year, turns out i had a cracked innner clutch cover, good news is they sell on ebay all the time for around 50-60 bucks, and they are not hard to replace, bad news is there is no fixing that one you have to et a new one, they sell new for 130, but thats what your problem is


its cause by pressure from the kickstart mine split right beind the bolt hole you will see what i mean when you take it off
[/b]
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didnt see the reply here. Inner clutch? Do you mean the magnesium clutch cover? It looks that I would need to replace the whole right side cover....How long did you let it go? Did it get worse?
 
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#4 ·
i did have the same problem and it was a cracked case, i took it to my local dealer and they told me it was caused by kick back,when you give it gas when kicking it over,the dealer fixed it and told me if it happened again it was on me.i did a have a problem with the gasket sealing,so i used honda bond to hold the gasket in place.
 
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#6 ·
You can repair most of the cases... jb weld works nicely on the material... I have used it on my clutch cover to keep the crack from leaking... no issues to this day[/b]
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sweet thanks guys. I'm suprised that a honda would crack on the side cover. My kickback is immense though (b4 i learned no gas, also coming off a 2 stroke). I did clean it with carb cleaner and try to jb weld it, but after it cured the case was still seaping....even before starting it. pisses me off. i scraped off all the jb weld with a flathead, sanded it, and went big on some good hi temp silicoln. havent ridden it yet to see if that works.
So basically, dont let the bike kickback and the problem wont get bigger? How the hell are all the CRF bikes not having this problem?
Thanks
C
 
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#7 ·
Try to be as easy as possible on your kick start. I never get kickback but mine still cracked. My decompression spring broke so I was kicking full compression for a while. The thin side case cover is all that supports the kick lever and it's only a matter of time before it starts to crack on the 04/05 at least. When I ride I try to stop on a hill so i can roll start it.

So if you do crack your right side case cover, when you get the new one you can reuse your old mechanical seal if you are careful and cut it out of the old cover without damaging the seal. (the side case from honda does not come with the seal or bearing) This way you the only additional part you may need is the gasket.
 
#9 ·
I am a welder....I would just zip the crack shut with my TIG welder. But thats the luxury of being me.

For you, take right side cover off, clean it up really good and get the oil off. Then take it to a local machine/welding shop and have them zip the crack shut and reinforce the area with some cover passes. Pull the seal out first or you will melt it.
 
#12 ·
Just think of the right crank case cover as one big drain plug for both engine side oil and clutch/tranny oil, although they are separated in the motor. It will blow your mind, but you can fill it back up when you put it back on.

You see the bottom holes? They go all the way through and the tranny drain area and plug is above that.

Why don't you all take a nice look at my crack while your at it lol j/k

I have this for sale and it can be repaired, I just never did because it barely leaked. I also had one repaired and juice is on the money with his advice.
 

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#13 ·
Ok........I did check it for cracks because of the reading I have done here. I didn't find any cracks at all. But I did see where the gasket was all screwed up. Maybe from when the guy before me had it. So I'm replacing the clutch(which is why decided to tear it down in the first place), and putting all new gaskets
in it.
 
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