cracked ignition cover

[Rema1000]

The previous owner dropped the bike on the right side, and the inigtion cover (labelled "Suzuki" with three screws) has a crack in it, right at the bottom, and running about 3/4", almost up to the edge of the flat center part where the screws are.  It's not just a hairline crack: if I run my fingers over it, I can feel a gap.

Should I seal this, for example to keep water from splashing up and getting in?  I assume that the cover gets pretty hot, so just putting duct-tape on the outside is probably not the answer!?  Maybe taking the cover off, sealing the crack with Permatex form-a-gasket, making to wipe-up any that gets inside?

[wingbolt]

I was looking at replacing those Suzuki covers as the previous owner's wife dropped my bike in the driveway while he was trying to teach her how to ride it.  I think those are stick on covers.
See Parts 13 & 18 on this schematic:  http://www.bikebandit.com/partsbandit/showschematic.asp?dept_id=138248
Once you get the part number, you can plug it in to bikebandit and they'll give you a price.  If I recall, they're not cheap.

Hopefully, that's where the crack is located, and not on the crankcase itself.

[Rema1000]

Sounds like you're referring to the "emblem" stick-on part 68233-01D00.  Looks like I need the Suzuki part 11381-01D10 "cover, contact breaker", vhich is Bike Bandit part "COVER,CONTACT B 477163-001" for $31.02 .  But it seems like this part just keeps dust off the generator.  Other GSTwin members report that when their seal on the crank there goes, you get oil dripping from the generator cover, so it's not oil-tight anyways; so I thought I could get-by with just sealing the crack shut against outside dust and water.

[average]

31.02?  I went to Barnett Suzuki (raleigh,nc)   and the kid there who was atleast 10 years younger than me said 110! i left as he asked how i would like to pay for it :nana:

[StanFry]

I took a piece of sheet metal, traced the cover, cut it out with a Dremel (10 discs), placed the resulting cutout on a roll of masking tape, used a socket and a hammer to reproduce the curve, painted it black to match the bike, and glued it on.  Looks better without the advertising.

I had the discs (they're cheap) and a piece of sheet metal around.

Stan

[JohNLA]

Good tip Stan.

[miket]

31.02?  I went to Barnett Suzuki (raleigh,nc)   and the kid there who was atleast 10 years younger than me said 110! i left as he asked how i would like to pay for it :nana:

Barnett overcharges for everything. Try Kaw-Suz of Durham. Or take a ride to Ron Ayers if you have chance.

[yamahonkawazuki]

dont feel bad, mine was dropped there also, but not a crack, a hole!, but nothing leaking , no collateral damage on the case, so its not exactly high on my list of priorities

[Bob Broussard]

Mix up some JB-WELD and fill the crack. Then sand it smooth and repaint. It will look like new.

The emblems are around 20.00 bucks.