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  1. #1
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    Default Broken case...going to take some creativity to fix

    Anyone ever run across this problem? Pulled the inner primary on dad's old FXR to reseal everything. It's been leaking forever between the engine case and the inner primary. Well, this is why... the piece was still there, but it was cracked to the point of it falling off as soon as I touched it.



    I think I am going to take it to work and see if we can mount it on the mill. If I'm careful, it might even be able to be done without tearing the motor down very far. I want to mill a circle around where the lip should be and cut it about 1/4" deep or so. Then hopefully make a new one from aluminum and press it in place.

    If that don't work...
    Last edited by TimberwolfFXDL; 04-19-2015 at 3:51 PM.

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    VT No: 16-0692
    Alternator repair steel ring.

    Last edited by Dragstews; 04-19-2015 at 5:05 PM.

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    There are gaskets available so a guy could just mill it flat "field expedient repair" cheap and easy maybe not the "correct" way but it works.

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    The way dragstew is recommending seems the best, although installing it without splitting cases would have to be pretty creative. I have used the repair gasket from James, if I didn't want to pull the engine and
    Split the cases, or just go to a dry primary and forget abut it. Here's the info on the gasket.



    http://store.jamesgaskets.com/produc...roducts_id=148

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    Check your tranny mount plate and see if it's loose, that or a wreck is usually what causes this.

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    that repair ring is $150 though... ouch. I ran across that gasket kit as well... might just go that route instead.

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    Quote Originally Posted by panheadjess View Post
    Check your tranny mount plate and see if it's loose, that or a wreck is usually what causes this.
    yeah, I am going over the whole thing bit by bit. Hasn't been on the road in 5 years or more. I found a lot of bolts had vibrated loose or completely missing. The motor was built pretty stout 15 years ago or so. Could be any number of reasons it got damaged, but thanks for the tip, I'll check it out as well.

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    The steel ring install is not an easy fix to do....

    Gutted the motor down to just the bare case, then a lathe with at least a 15" swing and four jaw chuck was used to do the cut..
    Left a tight fit and used two ton epoxy

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    Quote Originally Posted by Dragstews View Post
    The steel ring install is not an easy fix to do....

    Gutted the motor down to just the bare case, then a lathe with at least a 15" swing and four jaw chuck was used to do the cut..
    Left a tight fit and used two ton epoxy
    I wouldn't even mess with doing it on a lathe. I'd index the case off the cam cover flange, and clamp it to the table of the mill. Find center of the circle by touching off the crankshaft snout, and then program the mill to cut a circle of the correct diameter. That way the table moves, not the engine. Should be able to be done without tearing down the motor much at all. Just needs some very thorough masking.

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    Yeah, guess you could do it that way, the pinion shaft sticks out past the gasket surface though, so you'd have to set it up on some 123 blocks or something, then you couldn't get right over them to clamp straight down, I'm not much on "clamping over air" it tends to distort the heck out of the workpiece, especially when it's aluminum. If you're gong to do it in the mill why not just go ahead and split cases? I probably would anyway at this point, that way you know what you have. It takes what? An extra couple of hours, some case sealant, and a sprocketshaft seal? Then you can check your main bearings, and crank runout, and ride with confidence.

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    Quote Originally Posted by TimberwolfFXDL View Post
    yeah, I am going over the whole thing bit by bit. Hasn't been on the road in 5 years or more. I found a lot of bolts had vibrated loose or completely missing. The motor was built pretty stout 15 years ago or so. Could be any number of reasons it got damaged, but thanks for the tip, I'll check it out as well.
    If it hasn't been on the road for 5 years, I'd like to make sure there's no rust in the main bearings, especially if it was stored with used oil in it, combustion blowby creates acids in your oil, and moisture can condense in there over that much time.

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    ... Whoa ...

    That gasket deal is sounding better by the moments...


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    Quote Originally Posted by Dragstews View Post
    ... Whoa ...
    That gasket deal is sounding better by the moments...

    Yeah, I did one for a guy that didn't want to pay for the other way, it has a bunch of miles on it, and seems to be holding up well. Makes you feel a little dirty when your doing it though, standing there with an angle head die grinder and that goofy look on your face. 😜

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    Check out this video. FF to the 2 minute mark, they are repairing that spot

    https://youtu.be/jIcqUcDcmKk

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    Quote Originally Posted by panheadjess View Post

    Makes you feel a little dirty when your doing it though, standing there with an angle head die grinder and that goofy look on your face. ��
    As always.... Dumb looks are free....!!! ... ...

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    I wonder if instead of grinding it and using that kit, could gaskacinch or similar case sealing adhesive be used? I have some heavy stuff still from when I put my buell case back together

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    I would think that gaskacinch would be really weak for that application....
    Two part epoxy may be overkill.... Be hard to get it apart without further damage the next time it needed service....
    Perhaps Yamabond would be the ticket.... ???

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    I do have some yamabond here...

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    yamabond

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