Holed Engine Case

A few days ago I posted that my drain plug fell out. Today was the first time I could look at the bike in daylight. (Had to fly out on 15th, not back until 20th, had to work Saturday, and here we are.)

Turns out the drain plug was not the culprit - still safely in place. Evidently something struck the bottom of the bike, sheared off a small fin, and broke another one which opened up the engine case. Hopefully here is a picture:

So...JB Weld? Remove engine and weld? Other possible fixes?

JB Weld. It will have to be really clean and oil free. Others may post a more elegant solution but have had JB Weld work on similar issues and years after no issues.

I'd start an insurance claim.

I'd start an insurance claim.

This.

You can/might/most likey fix it by JB or similar...

but, upon sale/trade/further complications, you are out of luck by a lot.

We would never accept such a repair as a trade in because resale liability too great.

Talk to insurance, it is why you have it.

Best wishes.

A few days ago I posted that my drain plug fell out. Today was the first time I could look at the bike in daylight. (Had to fly out on 15th, not back until 20th, had to work Saturday, and here we are.)

 

Turns out the drain plug was not the culprit - still safely in place. Evidently something struck the bottom of the bike, sheared off a small fin, and broke another one which opened up the engine case. Hopefully here is a picture:

 

 

So...JB Weld? Remove engine and weld? Other possible fixes?

 

Morning Hank

I have welded up a couple of 1200 engines with similar lower

crankcase damage. (not a difficult weld IF the person doing the

welding is very family with welding on oil contaminated

castments)

ALL the oil needs to be removed & cleaned from around, & even

close to the intended weld area. (oil migrates to heat so the

surrounding areas need to be completely oil free)

In any case the suggestion to contact your insurance company is

a good starting place. If they will cover it then you will probably

either get a new engine case, or new engine, or they will total the

bike & pay you the current value.

If you want to go forward & repair the damage (or have it repaired)

then possibly clean the area around the damage, work something into the

hole with a wire on it to plug off the hole from the inside (wire is

so you can pull the plug back out). Plug is used so no cleaning debris

enters the engine while you clean & roughen the surrounding area enough

to hold a Devcon epoxy (or JB weld). Case needs to be super clean of any oil

residue & case needs to be roughened enough to hold Epoxy.

Then after extremely clean apply Epoxy on an aluminum repair piece (you

can't just epoxy up a hole that large)

Once the epoxy is cured then fill with oil & run the engine/ride the bike

to see if any engine damage from running without oil in it.

Maybe then ride it a week or two to make certain that no engine damage present.

Once you ascertain that no engine damage present then find a (GOOD) machine or

welding shop that make a permanent (weldment) repair to that hole.

Devcon or JB weld will hold for a while (maybe even a long while) but there is

always that looming chance that the engine case will get very hot in use or oil

will migrate into the Epoxy to case joint then the Epoxy will lose it's seal.

Personably I wouldn't rely on an Epoxy repair to hold up for a permanent repair

on a long trip motorcycle. (it might but then again it might not)

If you do plan on a home repair using an Epoxy product then at least try to work a

backer into the inside of the case then run a screw through an outside repair piece

& bolt it (through the case) & into the inside case piece (be darn sure that inside

engine rotating parts clear the repair)