It seems as if a bolt rattled loose on my case below the bolt which has the exhaust bracket mounted to it. From that bolt rattling loose, too much pressure on the next bolt up, which already has a bracket mounted to it, causing the case to crack. I guess this is an instance where some red loctite would have saved me $400. I'm going to try TIG welding it back together and use it as a spare just in case it happens again. Just something to think about next time you have your case apart.

here is a little advice to give u. when mounting any after market exhaust. run the brackets up snug and than check to see if a spacer is needed. before u tighten down the exhaust. it will relieve any undo stress on the case bolts resulting in bolts breaking or bolts backing out do to the stress. i also take a marking pin after i torque the bolts. and mark the bolt and the case that way u can do a quick look to see if bolts are backing out. hope this helps.

That makes sense I'll do that when I put it all back together. Last time I had it apart and put it together I tightened the case bolts first. I've got the motor off the frame this time, I'm just going to put it back together off the frame so all the bolts are easy to get to.

ya is really a stupid problem. Mine is in same shape. Call Andy he'll set you up I got mine here waiting on parts . I'm popping a cam and hi rev coils in mine while its down. Good luck fixing it man. I think I'm going to dip my whole motor in red loctite lol

Torque it all down first and then back them out one by one and put the loctite on. If its vibrating out look for a source of vibration (prop/outdrive are common culprits).