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franktom

Broken kickstarter guide in the crankcase - am I screwed?

7 posts in this topic

The guide in the crankcase for the kickstarter shaft broke. It broke about 75% of the guide off at the base. Since the guide is cast into the crankcase is there any way for this to be repaired or am I screwed?

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If you mean the cast aluminium part, then I'm sorry to say that you wil have a lot of trouble welding it back in. The problem is that aluminium is porous, goes brittle with age/heat(work hardens) and also manages to absorb a fair amount of the engine oil. When you try to weld it, all that happens is that is spits, pops and generally makes a real mess. At best it might just hold for a short while, but the only real solution is a replacement....sorry. Any other thoughts from the other guys???

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According to my aluminum welding guru, another reason for the spitting

is that those cases are made of an aluminum/magnesium alloy and the

stuff is extremely difficult to weld. Also, if it ever catches fire, it can

be nearly impossible to extinguish.

Rgds,

Bob East

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you might be able to have it bored out and put in a brass sleeve or you might get lucky and find a drill bushing the right size and have it pressed in.

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The guide in the crankcase for the kickstarter shaft broke. It broke about 75% of the guide off at the base. Since the guide is cast into the crankcase is there any way for this to be repaired or am I screwed?

anyone else have this problem ? Any preventitive cures ? Will we all eventually have this break ?

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The guide in the crankcase for the kickstarter shaft broke. It broke about 75% of the guide off at the base. Since the guide is cast into the crankcase is there any way for this to be repaired or am I screwed?

I fixed a big chuck of missing case just under my flywheel cover on my 1979 Xs1100f with JB weld. I shaped it with a dye grinding tool and even drilled it and tapped a thread. I have read posts of people using JB weld to fix holes in clutch covers and cracks in cases.

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Thanks for the great ideas guys! However, I don't think there is enough surrounding material to "hold" a sleeve or bushing. The guide is load bearing and is about 1-1/2" deep so I don't think that JB Weld will have sufficient strength - given the extent of the damage. It looks like my only two options are: 1) find a replacement crankcase or 2) part the bike out and sell it piece by piece. :applause:

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