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Kenaroo

broke case.. do I need to machine match??

17 posts in this topic

PA250012.sized.jpg

long story short, I broke off a piece of the right crank case during rebuilding. I went to pry back the spring for the shift indicator and snaped it off at the case:mad:

Can I order just the right side case or do I have to order a machined matched pair of right and left side cases?

anyone with experience on this???

Yes... after I did this, My wife found me in the corner of the garage huddled up sucking my thumb:cry:

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In general if there is a gasket then the parts don't come as a set. The cases use gasket between the halves so you are good to just replace one.

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Being a mold maker I can say in theory they should be machined to production tolerances,and work from one day to the next.Left to right

If your hoping the left and right case halfs tolerances wont vary over several years.

Good Luck.

Save yourself the concern and buy as a set .

I swapped parts into YZF450 and they came as a set only (if you own one buy the case /chain guard the chain may brake off clutch lever boss near output shaft if it comes off rear sprocket)

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i would at least match the cases side to side without gasket and put a few bolts in just snug and see if you see any variances in the machined surface, then if you see anything not lining up you can go from there. cases aint cheap im sure.

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I would have it welded as well. that is not a high load area and with that cleaned up it should weld fine.In the sac area you can check with Kelly hoffer at meticulous... he's good

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Thanks for the feedback.. yeah.. I'm bummed. the case ran $280 plus change. didn't want to deal with popping out the old (new) bearings and seals so I ordered new ones as well.

I'm going to see if the new case will match up and I'll go from there.

IF not.. I'll try the weld job. I think that will be harder than you guys think.

I got a guy who is a aluminum/titanium welding specialist. if the new case doesn't match up, I'll take the old part to him to see if he can fix.

If that doesn't work.... I'll be buying a matching set of new cases.

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I had a similar problem with kickstart shaft hole, I was told by welder that you can't weld it because the aluminum is pourous and the oil will interfere with TIG welding process.

so I had to buy a new right half from hondaparts and it fit perfectly,

I had to wait a month because it was not in stock.

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Thanks for the input Suharianu::busted:

that's what I was looking for.. a real world experience replacing a case.:worthy:

Hope that mine fits perfectly as well

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my xr600 clutch case got cracked where the oil banjo bolt enters the oil filter case.was letting pressure blow out oil.Was welded 2 years ago and is still good.but was expensive.75 euros

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Got the new case in last night and did a fit test.

I'm good to go. everything lines up and spins freely.

so the "case" is solved (punn intended). It's not nessacary to match cases if you break one. just buy the part that's broken and it will match up (in most cases) to the existing.

Thanks Honda for keeping tight tolerances in there production casting parts.:busted::worthy::ride:

time to put this engine back in it's home and go riding :blah: :blah:

I'm still going send the old case to my welder to see if he can repair it. "just in case"

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Got the new case in last night and did a fit test.

I'm good to go. everything lines up and spins freely.

so the "case" is solved (punn intended). It's not nessacary to match cases if you break one. just buy the part that's broken and it will match up (in most cases) to the existing.

Thanks Honda for keeping tight tolerances in there production casting parts.:busted::worthy::ride:

time to put this engine back in it's home and go riding :blah: :blah:

I'm still going send the old case to my welder to see if he can repair it. "just in case"

A dirty little secret is that Honda is the ONLY manufacturer that you can buy one half of the cases. Of course this was as of around 10 years ago. But I think it still holds true today. Happy for you anyway.

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I think the type of bearings make the differance on the lower end.with rollers you have more room to work(not much). but with sleve type they must match.

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On the old sportsters you even have to line ream the outer case to the engine case for new cams it's a special tool thing .

Your right about honda tolerances as I stated alot of mating castings have these isues.

don't for go changing the other half bearing though they should always be changed as a set .

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