Urgent help required!

[kingoftheswing]

Hi guy's,

So today I have been servicing my bike, when tightening up the sump plug I have managed to snap the casing around the bolt hole. I think I have given myself a rather big job now!

Would it be easier/cheaper to swap the engine out, or to change the casing?

[kingoftheswing]

http://i977.photobucket.com/albums/ae25 ... 242e3e.jpg

http://i977.photobucket.com/albums/ae25 ... 168de3.jpg

[knackeredMk1]

Really tricky that .

You could use 'Chemical Metal' or similar and try to botch it but it will only last a while. There is the possibility of the whole plug dropping out and emptying the gearbox without you knowing ..... massive damage.

Proper job would be to take the engine out get some weld in there and redo the thread, or replace that side of the casing.

Probably most straight forward and easiest in the long term would be to get a new casing.

Bad news .

[kingoftheswing]

Any idea how much I would be looking at paying for a new casing? Or when I would find one?

[knackeredMk1]

Best buy as a pair, though it would probably be OK if you bought one side. eBay - £50-£100 (none at the moment). Or Leisure Trail for somewhat more.

Someone on here might have a set?

[kingoftheswing]

Excuse the profanity, but, FUUUUUUUUUUUUUCK!

Now that's out of my system, I am going to start the process of stripping the bike down.

Thanks for the advice.

[fallenmikethebike]

Steve's spot on , however, another temporary bodge might be to drill out the drain plug, and tap a thread into that, then set the plug back in with the best heat proof glue/thread lock, you can lay your hands on or chemical metal the threads.
The oil can then be drained through the new hole, though it will take longer, and best done when the engine is hot.
Yes, it's a bodge, but it might get you out and about while you source a new/ replacement casing.
Mike

[knackeredMk1]

You might be lucky as the other crank case is more often damaged due to the chain coming off.

[fishtail]

this fills me with fear ! screwing the thread on the case is quite easily done?

[kingoftheswing]

Right, I will keep you guy's updated on my progress with this.

I have so far today got the engine ready to come out, stopping for the evening now and I will crack on with removing the top end in the morning, that's what I have been struggling with toward the end of this afternoon.

I have the piece that is broken off, and my friend has a guy that's a pretty handy welder. I am going to take it to him and see if we can get the broken piece welded back into place then get the thread re-done.

While it's in pieces, I have figured that it's senseless wasting all this effort, so I am going to turn it into an entire project.

I want to clean it all up and paint it and I need to sort out all of the electrics as they're a bit tatty. That is what I have planned for now but I'm sure as I press on there will be more and more, bit's and pieces that I will be sorting out.

Thanks for the advise thus far, please expect a lot more questions!

[kingoftheswing]

http://i977.photobucket.com/albums/ae25 ... 37b7a9.jpg

http://i977.photobucket.com/albums/ae25 ... 9dac40.jpg

This is my progress so far. Any tips for removing the top end?

[knackeredMk1]

Easiest to take the radiators of and then you can remove the engine in one piece. You can do it like it is if you remove the conecting pipes ...................

[clint]

I feel like crying I still love that bike and it isn't mine anymore

[clint]

I'm dying to see the ffinished project though. I never got round to making it how I wanted, after I rebuilt it I just rode it. Had big plans of doing "a knackeredmk1" on it

[kingoftheswing]

I have disconnected all the pipes, engine is all disconnected. Just can't negotiate it out of the frame