fix broken cranckcase houisng mate..????

Hi everybody,, I am a newbie here on this site. But I have been riding for a while but just casual sightseeing kind of rides.

Anyway,, I just recently picked up a junker project 96 vfr 750 and was wondering if anyone could offer some pointers. I am okay with general mechanical repair but not anything on engine side. Well the bike was a crashed bike, mainly rightside crankcase cover and its mate housing which I believe is part of main engine casing. There are some other plastic, cosemetic stuff broken but front end suspension seems okay and rear end is okay other then the all the plastics. I am hoping the frame is not cracked, doesn't look from outside but maybe inside.

I took off the broken clutch case cover off, most off all the wires harness,couplers, connection are all broken and chewed up..
So anybody know if its worth to repair cheapely or just get new used engine..

here is pic of what I am talking about.

 

I have done quite a bit of tig welding on engine cases and it can be very tricky at best. If you have the broken portion I would advise the J B weld route as welding it is going to require the engine to disassembled. If you have the part that is broken out J B weld it in place and carefully file that portion down to match the rest of the case where the gasket seals as it will sit high. You will have to be careful when you tap that bolt hole but it can be done. Not alot of options when this happens and this is by far the easiest and in the long run only you will know. Done many times over the years.

 

Am I smokin crack or are there two bolt bosses snapped off along with the third boss and a big ol chunk o engine block???? You're only saving grace is that it's at the top of the engine and oil tends to leak from the bottom. I'm gonna go +1 with Toe for some JB weld if you have the old pieces cause the other way around is going to be a major undertaking. Just about anything that is a cast metal is a major PITA to weld from what I understand, glue that sucker back together and ride it like it's stolen!! Oh, and :welcome:

 

thanks for the info.. no I don't have the original broken piece, looks like it flew off at the crash scene. I was thinking JB weld if I had the original piece. Is it easy to fashion a new piece out of the large broken clutch case cover and somehow make it fit.

Also if not tightly sealed,, how much oil will spit out. If I take it a local welder,,,do you know how $$$ they usually charge for this.. Get this , the motor or bike has only 5400 miles on it when it was crashed and into a bike lot. There it collect dirt,dust and crap...but the gas tank inside is not rusted, looks like somebody put stbil in it, but tank is dented.

Otherwise I am going to have to junk this motor up...

any idea how much new used motors on ebay go for... but I am thinking streetfighter look if it doesn't cost that much.. Otherwise, I am just going to use the rear swingarm and rear wheel for my honda hawk gt mod and part out the rest of bike.

thanks,,,guys,,,was hoping for easy solution but looks like more work then I planned for. I like to work on it but have other projects and won't have time for this one now.

 

EDIT...

I figured it out.... a way to fix your bike after much thought about it.
You will not have to remove the engine.

OK...Here is what i would do and I have a lot of experience with these repairs.

First clean the broken areas with brake or carb cleaner. (watch your eyes!!!)

It is real lucky it is the top of the case!!!

Then go get three metric studs for those three holes. NOT BOLTS -studs.Threaded on both ends.
Carefully thread in the three studs into the holes (dry run.) Do not over tighten!!
Then when you have that Put them back in using the JB weld. Build up the area that is broken off on the case around the stud. Let dry overnight.
Remember the area you put the JB weld must be clean and sanded with sand paper so it has a good tooth for the JB weld epoxy.

All that is left is the missing piece. Make a pattern and get a piece of aluminum and using a hack saw and a file carefully make that piece the best you can.

Next put on a new gasket using Gaskacinch case gasket glue. On both sides ...let dry ,then slide on the gasket so that gasket is hanging from those top three studs. Put Gaskacinch on the outer case too, and let it dry before assembly.

Now glue in the piece you made out of aluminum into that simi circular space. Using the JB weld epoxy. NO JB weld touching the gasket.

Slide the outer case onto the studs and put a couple bolts in the bottom to start. All finger tight. Get all the bolts started by hand. make sure the piece that you made is in position and the gasket is in position and just tighten all the bolts AND THREE STUDS lightly. Wait over night and and then finish tightening all the bolts. Do not tighten the nuts on those top three studs very tight.

Go easy.

All you are trying to do is keep the oil in the case.

After the jB weld on the studs is dry.

 

I guess you ARE smok'n crack. There are three bolt holes with broken castings. LOL..

 

Many "local" welders will not have the experience or proper equipment to deal with this.
If you DO decide to get it TIG welded the case must be clean enough to eat off of. And that will require complete tearing down of the engine.
SEE my other post for a REPAIR option which looks quite viable.