wht180,
I asked my dealer about your problem and he let me know that they come with coolant in them so if it happend to yours it should have happend to all of them. i am just confused cause your problem should have happend to every z400 cause im sure the factory uses the same coolant in all the quads.
It has happened to
EVERY 05/06 with the magnesium clutch cover (Just pull the cover and you will see). Its simple chemestry. you can mix water based coolant with cheap magnesium.
Now the worst part is, they handed me back a pitted, corroded and out of round part and word out of their mouth..."its fine, just put it back on your quad and you can fix it yourself."
All I got out of this whole deal was a free side cover paper gasket. but I had to put my own motor back together on my own. They handed me a dis-assembled quad.
Trust me when I say this, Suzuki does not stand behind all their products. Myself and many many other Z400 owners (check Z400central.com) are all in the same boat. We have been left high and dry. Suzuki knows this problem will not affect (destroy) most motors untill they are beyond their 6 month warrentee.
So their stance is to call it good and let it fail out of warrentee. Or to let us spend our own money buying the 03/04 clutch covers for $150.
That quad of my wife's should have been fixed no questions asked. That coolant passage started as about a 3/4" round hole. now its about 1/16" bigger than stock and jaged egg shaped.
Just don't be suprised if/when you get the same treatment on an LTR.
This problem should not be an issue on the LTR, But one thing I do have this morning...... is a reminder that Suzuki has just recently burned me