Can this be fixed? Chain busted case

[JerseyDirt]

Coming back from some trail riding today, last stretch of road, master link gives and chain slams into case. The POS stock case guard just folded and actually forced the chain to rip into the case cover grinding out a groove and busting through one part, as seen below. Does anyone know if this can be fixed (welded) or do I need to pull the motor and split the case?

Here is the link to the image. I can't get it to instert into the post.

http://www.flickr.com/photos/samadams/5673696706/in/photostream

Edited April 30, 2011 by JerseyDirt
picture

[johndeerekid]

yikesss. well if you were going to weld it you would have to pull the case off to do it anyway so that you dont screw any of the internals up., so no matter what the case has to come off. just depends whether you can find someone that will weld it for you. -Wes

Edited May 1, 2011 by johndeerekid

[woods-rider]

I agree with johndeerkid, it can be welded, but you should split the cases anyways to prevent damage to internals.

[dgcars]

For a permanent fix, go with the above. I done a temorary repair once with JB weld on pretty much the same area & damage. After 3 years it still hadn't leaked or come off, so I left it alone......

[JerseyDirt]

Thanks guys. Pulling the motor and splitting the cases is a bigger undertaking than I have time for right now. I would have to pay a dealer or mechanic to do it and I imagine that would cost about as much as half the bikes value.

I think I will try JB weld and see if it holds. If not, I will have to decided if it's worth fixing or if i should sell it and use this as an excuse to upgrade.

Thanks again for the advice.

[the_smoo]

I had something similar happen to my kx250 several years ago. Chain came free and chewed out the clutch actuator on the case. Completely destroyed it.

The bike was not worth pulling apart and re-doing as it was a play bike anyways.

I booty-fabbed up some JB Weld and made a metal plate that I screwed into the sprocket cover bolts. JB Welded over that. Despite everyone saying I needed to pull everything apart and repair, I managed to ride that bike for another two years before it was stolen. (hopefully it soon came apart after the theft!)

Wasnt ideal, but it worked. Of course if I had the time and money, I would have done it properly..?

[the_smoo]

yes it was a frankenbike! in this pic, I am tearing it down for a much needed clean and overhaul! The arrow points to the clutch area that is all JB weld and was completely missing after the chain chewed it out..

[Sknight]

If you decide to JB it take some rough sandpaper or a burr and really rough up the area to give a good surface to adhere to, then clean the area and the surrounding area really well finishing with brake cleaner. Use regular JB weld and I'd apply it around the hole first then kinda close the hole up with it if that makes sense. Prevents a big wad from going into the case.

[dgcars]

....I'd apply it around the hole first then kinda close the hole up with it if that makes sense. Prevents a big wad from going into the case.

Use an old feeler gauge or a thin piece of 'scrap' metal....no worries ?

[the_smoo]

If you decide to JB it take some rough sandpaper or a burr and really rough up the area to give a good surface to adhere to, then clean the area and the surrounding area really well finishing with brake cleaner. Use regular JB weld and I'd apply it around the hole first then kinda close the hole up with it if that makes sense. Prevents a big wad from going into the case.

Use an old feeler gauge or a thin piece of 'scrap' metal....no worries ?

look at all the booty fab specialists!

[JerseyDirt]

Well, since the JB weld was $6.99 I figured I had nothin to lose. I roughed up the surface with a dremel, cleaned everything with brake cleaner, and then I plugged op the small opening with a piece of bread. Put the bIke on it's side and laid a nice layer of JB over the hole and surrounding areas. Now I have to give it 24 hrs to cure. Fingers crossed.

[dgcars]

look at all the booty fab specialists!

?

[dgcars]

....and then I plugged op the small opening with a piece of bread....

Wholemeal or sesame seed....?

[Sknight]

Use an old feeler gauge or a thin piece of 'scrap' metal....no worries ?

Yep, just need to make sure you can get full coverage around it!

look at all the booty fab specialists!

Hey man when you spend a large portion of your life broke or worse you make do with watcha got! You would not believe some of the stunts I've pulled off before. Rigged isn't the half of it.

[JerseyDirt]

Wholemeal or sesame seed....?

Don't be ridiculous. You know the sesame is for hamburger buns only:lol:

Just a tightly packed piece of potato bread that will form a temporary plug for the hole while the JB weld sets over it, and then is harmlessly eaten away from the inside and flushed out in the next oil change.

[JerseyDirt]

Well, a big thanks to all the JB Welders who said it could be done. So far so good (knock on wood).

Definitely cheaper than tearing out the motor and splitting the cases. Let's hope it holds. Rode about 10 miles today with no problems.

[ZRT800guy]

they way i fixed myLTZ 400 cas was i took gas tank repair since its like a putty and used that to fill the whole and then covered it in JB weld and it worked perfect until the chain broke again and really screwed the case.....

[fixitandy]

the same thing happened to me once you remove the stator case you will see that there is an oil gallery that is feeding the clutch actuation arm needle roller bearing you have to remove bearing (with tiny puller or carefully drill or die grind it out)& insert a brass rod down gallery tube ,tig weld over hole remove brass rod file to nice finish and your done.make sure the area is thorougly free of oil & all residues for a perfect weld (I went around all the local hardware stores & bought brass hinges for their pins to insert down tube snuggly) good luck Andy:thumbsup: