XS1 Crankcase Repair

[Dinner200]

So I’ve got an early 3/1970 XS1, drop dead gorgeous bike with only 8500 miles. Ran awesome until eBay sent me the wrong chain which proceeded to break and send itself through the cover over the forward sprocket on the upper crank case. Bike still runs fine but I’m devastated, I love this bike almost as much as I love my gf. I was going to completely disassemble the motor and send it in for welding but I know upon reassembly something will go slightly wrong and it won’t run right. That and only having 8500 doesn’t warrant a rebuild at the same time.

I would have just JB welded the chunk back on and used some engine enamel to make it look factory but the chunk that came off is warped in two axises. It sticks out and doesn’t look right. See the attached photos for details.

My question is can/should I try to bend the broken chunk back into shape, JB weld it back, and put a little aluminum plate over the not so good looking part or should I bite the bullet and disassemble the entire motor and pay an arm and a leg to have it welded up? This seems to be a common problem but none so severe as my condition.

 

[bosco659]

Sorry to hear of your misfortune. I too would be devastated if that happened to me. I like to fix things the right way so for me, I’d get it welded. Good luck with the repair!

 

[Rasputin]

Do you have a picture of the broken link?

 

[Signal]

Looking at the crack in gear selector drum bearing boss I dont think it will be long before you have gear selection problems or a large oil leak. It wont cost too much to get it welded but be prepared as welding may not work.

 

[Dinner200]

Looking at the crack in gear selector drum bearing boss I dont think it will be long before you have gear selection problems or a large oil leak. It wont cost too much to get it welded but be prepared as welding may not work.

The crack into the gear selector doesn’t go that far in. Looks like I forgot a photo

 

[Dinner200]

Do you have a picture of the broken link?

See attached photos in the first post

 

[DogBunny]

I have a set of perfectly good XS1B cases that I will sell to you very reasonably. VIN S650-010911. These are cases only, no crank, tranny, etc. PM me if interested and I'll send you pics.

 

[Dinner200]

I have a set of perfectly good XS1B cases that I will sell to you very reasonably. VIN S650-010911. These are cases only, no crank, tranny, etc. PM me if interested and I'll send you pics.

Sent you a message

 

[Hudriwudri]

Im sorry for your misfortune.
From what I can tell on that crack it should be very y easily fixable for a experienced modern age (hi frequency inverter) tig weldor.
The only pain in the axx is you might need to disassemble but even that might with correct welder settings and procedures not necessary.
I do stuff like that on a semi regular basis but unfortunately I'm in Europe so cant help.
Where in the Us are your located as i assume at least in California it should be a cake walk to find a capable tig fella.

Kind regards

Christian

 

[Dinner200]

Update: I was bending and filing the broken chunk with plenty of success. I had it dead on but it still didn’t fit quite right. It was then I noticed another crack in the shifter pin hole. That was the final mail in the coffin, I could glue the piece back but after however many heat cycles and the vibration of a 360 degree crank it’ll just break again and might screw something else up. I’m replacing the cases entirely now as I bought a pair from DogBunny very reasonably, definitely a lot cheaper than welding. Won’t be matching numbers but I don’t care that much