Author Topic: Crank case welding. (Read 4863 times)

davidkent · « **on:** 04 May 2015, 06:09:22 pm »

As above.
I've had some bad news and found my nasty tapping noise.

Basically there's a crack in the crank case on the circular hole that houses the water pump.

It's at around the 7-8 o'clock position but seems to be allowing the water pump enough movement to make a nasty tapping noise.

If I loosen the bolts and push the pump over a touch the noise stops.

The engine has recently had the cam chain and alsorts done so don't really want to be changing it.

Looking for anyone who has had this or similar, or somewhere that can repair or find a solution etc?

I'm in the Wiltshire area and can travel within reason.

Thanks in advance

pilninggas · « **Reply #1 on:** 04 May 2015, 08:15:43 pm »

Price Brothers in Avonmouth are not cheap - but they do lots of proper automotive engineering that others cant or wont do.

Give them a call and explain the problem.

davidkent · « **Reply #2 on:** 04 May 2015, 08:16:47 pm »

Wasn't expecting a reply so quickly.
I'll dig the number out later and call them!

Thank you!

pilninggas · « **Reply #3 on:** 05 May 2015, 06:50:05 pm »

Quote from: davidkent on 04 May 2015, 08:16:47 pm

Wasn't expecting a reply so quickly.
I'll dig the number out later and call them!

Thank you!

They do all sorts, diamond-drilling (for broken bolts, they even drill out easy-outs that have snapped), tig welding, spark-erosion. All the stuff that is outside the scope of my home or employers workshops.

davidkent · « **Reply #4 on:** 05 May 2015, 07:04:35 pm »

This sounds perfect.
I'm worried that simply welding the cracking won't be enough as the hole has enlarged slightly so perhaps they can repair it.

I'll try and get some pics before calling them I think. May make things much easier.

Didn't get to calling them today.

Cheers

davidkent · « **Reply #5 on:** 05 May 2015, 07:34:37 pm »

Updated with pics now!

Deefer666 · « **Reply #6 on:** 05 May 2015, 08:42:41 pm »

I have another set of crankcase for £50

davidkent · « **Reply #7 on:** 05 May 2015, 08:44:47 pm »

Buying the cases isn't the problem

Fitting them is the problem unfortunately
I wouldn't be able to do the job myself
plus the cost and the work I've done to mine.
not sure I could warrant it anymore but the bikes worthless as it is.

I'm totally screwed

Deefer666 · « **Reply #8 on:** 05 May 2015, 08:55:42 pm »

Replacement engine then ? I have one for £250

davidkent · « **Reply #9 on:** 05 May 2015, 08:56:53 pm »

What's the details? For a 2003? And cam chain all good etc as mines just been done?
It's an option tbf

b1k3rdude · « **Reply #10 on:** 05 May 2015, 09:43:31 pm »

@Dave, that looks like less of a crack and more of a extreme wear..? Regarding getting it welded, all you need to find is a good mechanic/welder that can do fine TIG welding on aluminium/alloy. Or even better find someone who can do do laser welding, I got a float bowl done this way and it was the most impressive piece of welding I have ever seen.

davidkent · « **Reply #11 on:** 05 May 2015, 09:49:11 pm »

It isn't wear definitely cracked from the impact mate.

This sounds interesting but if it'd near impossible or very expensive I've a leafy been offered an engine so need to weigh it up I guess.

My worry is if it's welded will the pump still be central and will it ever be oil tight again I guess :/

b1k3rdude · « **Reply #12 on:** 05 May 2015, 10:13:21 pm »

Quote from: davidkent on 05 May 2015, 09:49:11 pm

My worry is if it's welded will the pump still be central and will it ever be oil tight again I guess :/

If an engineering shop did the welding they would/should then mill out the excess etc to give you a perfect whole. If the replacement engine has lower mileag, in better condition, dosent need anything major doing, comes with the usual 1 month warranty and you have the cash then its the simplest fix.

davidkent · « **Reply #13 on:** 05 May 2015, 10:19:03 pm »

That's a lot of ifs but it's from deefer so I'd imagine it's all straight.

I'll pm him tomorrow for details.
my engine is low mileage ish so such a shame

Still. Spare part city haha

unfazed · « **Reply #14 on:** 05 May 2015, 11:22:54 pm »

Looks like the result of a broken chain some time in its past.

I do not think welding is an option without splitting the engine and centralising the hole to take the pump again would not be easy as someone has mentioned previously.

Deefers offer of engine might be your best option and he does have have a very good reputation on here.

Deefer666 · « **Reply #15 on:** 06 May 2015, 07:04:45 am »

I have an Ali welder in the unit next door to me, and that would have to be built up with weld and then machined back and by then the engine would be full of swarf and in need of a strip down and flush so you would be no further forward than if you had bought new casings. The way I see it there are two viable options either new casings or new engine, both are gonna be around the same price.Th

The engine I have is out of a running bike that was Cat B from a fellow foccer, but the engine bars saved the lump from any damage and bent the frame instead. Its a 2000 bike I will have to dig the clocks out to find the mileage.

davidkent · « **Reply #16 on:** 06 May 2015, 07:09:03 am »

If you can get all the info I need deefer id appreciate it.

Aren't the engines different in 2002-2003 models or is that rubbish?

Cheers

Deefer666 · « **Reply #17 on:** 06 May 2015, 07:51:54 am »

No mate the engines are the same. I have swapped from them from all models without hassle. Like I said if you need an engine its £250, if you want your engine rebuilt onto new casings, it'll be nearer £300 if you remove the engine and bring it to me.

davidkent · « **Reply #18 on:** 06 May 2015, 07:53:11 am »

Seems silly to do that when I could have a whole engine of spares too I guess.

Defo interested. Can you courier them or collection only?

unfazed · « **Reply #19 on:** 06 May 2015, 07:53:56 am »

Most important is that you use the rotor and alternator from your engine all the rest should be fine.

They were upgraded to improve the charging to cater for the dual headlamps.

davidkent · « **Reply #20 on:** 06 May 2015, 07:55:55 am »

That makes sense can't see theyre a hard swap

Deefer666 · « **Reply #21 on:** 06 May 2015, 07:59:28 am »

courier is fine, it'll go to my business address so usually no problems with carriers

Deefer666 · « **Reply #22 on:** 06 May 2015, 08:04:41 am »

You can use the late model alternator on an early engine its simply a case of changing the connection, the early alternator will also work on the late engine.... I know the alternator was upgraded but the old one works the on the new bike just fine in my experience, I'm guessing that you would only encounter a problem if you tried to run several accessories from it, like heated grips, heated clothing, sat nav etc all at once.

davidkent · « **Reply #23 on:** 06 May 2015, 08:14:54 am »

That seems reasonable to be fair.
most I use is sat nab and phone charger anyway

Assuming this engine is pretty up straight I won't need to do the cam chain or anything? Just swap my front sprockets over and get fitted?

If you manage to find the mileage that'd be great then we cN inbox re purchase.

I think it's the safe bet plus ill have a shed load of spares.

Is the engine complete?

Deefer666 · « **Reply #24 on:** 06 May 2015, 08:50:12 am »

The engine is complete apart from the front sprocket cover and its still in the frame atm. You wont have to do anything other than put new oil & filter in it and fit your front sprocket... It is a bit dirty so you may wanna take some time and give it a bit of a de-gunk before fitting it. I am working away from home from tomorrow until Sunday but can organise it on Monday