The broken crankcase at the starter idle gear; happened/happens to the bikes build from 02-05, early 790 motors with the old style crankcase breather.
They redesigned the crankcase breather and bridged the block in that particular area in the second part of 2005.
So in 05 there are bikes with the earlier crankcase breather style and the newer/current style.
Having said that, my Bonnie is an 03,the same situation happened to me when I was out of warranty back in January 06 and Triumph covered the expenses.
Carburetors backfiring was the cause of my crankcase failure.
