Broke my ignition pickup cover, need some help.

So, I wiped out in the rain last night and broke my "ignition pickup cover". Sure, I'll get a new cover, but what really troubles me is that the screw holding the cap on decided to take part of the insides with it.

Any idea how I should fix this? I though I'd thread a bolt into the remaining threads with some anti-seize and then rebuilding the missing part with some JB weld, unscrewing when it's set and then using that to secure the cap.

Does this seem like an "Ok" idea, or am I setting myself up for disaster?


Incidentally, does anyone know a decent place to get a replacement cover? I got a couple hits on ebay, but not as many as I'd expect. I tried searching "Ignition cover" "Pickup cover" and even "Points cover" and I still only get a few hits.

Here's a (poor) picture of the broken cover.

Sorry to hear about your fall. Hope your alright.

Other's have had good luck using JB Weld to repair that same area. Just not sure I'd have the bolt in there while your letting the JB Weld dry. Might be best to tap the hole afterwards.

I think kz650 points covers will fit as well, so that'd give you more of a chance to find one on ebay.

Would it be feasible to tap to a deeper depth and use a longer screw? Or maybe re-tap for a size larger screw?

Good Luck!

That's a pretty common cover, It was used on 550's 650's and 750's. There are a few different styles depending on the model year but as far as bolting up correctly they will all work. The one you broke is probably one of the most common.

l0g1c, Glad your ok and it was minor damage to the bike, here is a couple of "buy it now" covers on ebay....

$24.99, free shipping

$20.00,$7.00 shipping

Thanks, Bluemeanie (I think I have a Blue Meanies CD around here somewhere, hehe). I nabbed the first one you mentioned.

I appreciate the extra effort, man. I want it to be clear I wasn't trying to get someone to do my work for me. I just thought maybe there was some unknown Mecca of Motorcycles outside of ebay that I was missing (besides Z1 ). I came across that cover last night, but couldn't seem to find it when I went back tonight.

I've decided to take the advice I got here and just JB Weld and then re-tap the hole. I'll post pictures when I get it sorted.

Thanks again, guys!

A bit late but... have you thought of engine guards?

Best of success!

Just be sure you grind a little on the damaged area, and degrease after.

You could try to put some oil on the bolt, then put JB Weld around, in order to make the threads at once...You have to make sure the bolt is "loose" after its started to harden, but on this maybe the best is to make the threads after its hardened?.
You could make a mould of plastilin or something. Because the JB Weld is very thin before it starts hardening.

JB Weld will hold. I have very fine results after using it.

his points cover got lunched but i think we can salvage the screw holes in cases with longer screws.we straightened up a couple things on the bike but now we are only getting fire on 1-4 2-3 are dead no fire.switced coil wires and coil checked out.there was a lot of gunk up inside the electronic ignition we are gonna clean it out tuesday and ohm out the wires back to the ignitr and check wiring back to coil to make sure nothing got knocked loose in process of us working on it.

The early 650 covers were for points, and I thought I had a problem fitting the points-type cover onto a pickup-type ignition. The bolts line up, but the cover has a little less clearance due to its shape. I think the rotor-bolt either hits the cover or gets real close.

Yep, thanks again for the help yesterday, Plummen. She's gonna look real nice when we're through with her.

no problem,just need to chase down that little issue when im more awake !:laugh: