All,

While re assembling the alternator this morning this happened (see Pics),
I heard a crack which i thought was the alternator re seating itself when i notice the casing had cracked.
At this stage no undue force had been applied to the bolts and i had done them up a small turn each, so that they all tightened at the same time.

The crack is the top part of the case where the starter motor bolts into

So where to now, is it fixable or do i part the bike out and start over?

Aussie Johnno

 

You may be able to have it TIG welded back together. However, no promises that it will not crack again. This is now going to be a weak spot in the casing. Luckily it's not part of the cylinder wall.

 

1 Tap the stator in with a hammer - a rubber one. Crack should close
2 Have the crack TIG welded
3 Pray......
Bad luck Johnno

 

+ 1 a good tig unit will do it if they build it up on the casing

 

+1. It's gotta be welded and welded right. Wish you luck, johnno.

 

Looking at it in the good light of day i can see the crack has also gone inside at the base of the starter shaft hole, if that makes sense.
So in other words i think it is too far gone to try a fix. To do properly i would need to remove the engine, dismantle and split the cases so it can be cleaned up properly.

Aussie Johnno

 

A couple of close up photo's of the damage, worse than i first thought.

Aussie Johnno

 

That's really bad luck Johnno , maybe an engine transplant would be the easiest?

 

Nah Johnno I'd still give it a shot ..... see what a good tig Guy / shop says to ya

Tiggin' alum is more like braising than actual "welding" ......... a good tig Guy can amazing stuff..... seen some amazing repairs done to alum casings !

 

This is why I don't work on my bike. I'm just about this lucky.