Warning: Do Not Use Zenoah Clutch Housings

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DemonRC1

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I've been fighting a losing battle with a cracked rear crankcase fan shroud for a few months now. I really hurts when it's a $300 DS billet piece too. This weekend Camo busted his Zenoah clutch housing at all 3 bolt holes that mount to the gear plate. I just took some measurements and the Zenoah clutch housing is 1mm wider than the CY. So when using the Zenoah housing, you engine sits 1mm further away from the gearplate which causes the fancover holes to not line up. If you manhandle the chassis bolts into the fancover your crankcase, gear plate, and fancover are immediatly under stress. Add a few chassis tweaks from normal running and something will bust. This lessen cost me a $300 crankcase since DS won't respond to me and get me a replacement fan shroud.


I figured I'd just share this with you guys.
 
Picture 1 is taken with the Zenoah clutch housing in. The edge of the crankcase fan shroud sits 1mm to close to the fan cover mounting holes. Picture 2 is taken with the CY clutch housing. You can see the edge of the fancover sits further away from the mouting holes which is the correct distance. I double checked and the screws now go in smoothly by hand. Before when the holes weren't lines up I'd have to manhandle the screws in everytime.

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and here is one of the example's demon is talking about!!!!! :( but if you are the kind of guy that look at the bright side of things, it gave me a bit over half a gallon before falling apart :D

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huuuuu, almost forgot. here are the leftovers!!!!! LOL ;)

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rob64n said:
Now you guys will know why I took the stock gearplate spacers out of my xt and made new ones.
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I remember you telling me about breaking a fan cover cause of the hole line up. Where you running the Zenoah clutch housing too?
 
That why if you have a zenoah komatsu 4 bolt motor you have to switch to a cy clutch and cy fanshroud to get a direct fit in the mt/tt
 
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