Motorcycle crank case repair

  1. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    Just a little job I'm on with tonight.

    Yamaha TDM 850 broken starter motor mounting lug on crank case.

    Here is the damage......
    IMG_20180909_201531.jpg
    Cleaned up ready for Tig.....

    IMG_20180909_202241.jpg

    Build up with 4043 rods. Tig set to max 130 amp but using pedal.... IMG_20180909_203557.jpg


    IMG_20180909_203603.jpg

    Filed into shape.....
    IMG_20180909_205028.jpg

    IMG_20180909_205045.jpg

    Just need to put in mill to skim the surface level and drill / tap an m6 hole.
    Job for tomorrow now I think....
     
    lchris21, decca, ronan and 22 others like this.
  2. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    Fixed in mill. Had to raise it at one end with a few sheets of paper as the machined faces are about half a mm out of parallel.

    IMG_20180910_202150.jpg


    Milled the weld down... IMG_20180910_205440.jpg

    Light touch with some 400 grit to smooth off.., IMG_20180910_210231.jpg

    Then made some studs to get a reference center ......

    IMG_20180910_212617.jpg

    Measured centres with calipers. Luckily the man brought me a good spare case for measurement...

    IMG_20180910_213357.jpg

    IMG_20180910_213602.jpg
     
  3. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    Marked out the lines so they intersect...

    IMG_20180910_213701.jpg

    Drill...
    IMG_20180910_214728.jpg
     
    ronan, Rannsachair, RedOrZed and 4 others like this.
  4. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    Tap a new 6mm thread......

    IMG_20180910_215420.jpg

    IMG_20180910_215433.jpg


    Job done!!!
     
    Chillitt, Ruffian, decca and 20 others like this.
  5. MattH

    MattH Member

    Messages:
    3,578
    Location:
    Bristol
    Nice job. Did you check the concentricity of that bore after welding? I’d of thought it might of pulled out of round from the contraction of the weld filler.
     
  6. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    No I didn't bother. The bore isn't a bearing face, it's just where the starter motor locates so not super critical.
     
    roofman likes this.
  7. zx9

    zx9 Member

    Messages:
    3,421
    Location:
    South East London
    Good work, I was wondering how you located the hole centre, nicely explained.
     
    jpmillermatic and Fazerruss like this.
  8. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    If it had been a bearing face then I would have machined a tight fit plug to go inside and hold it from warping.
     
    doubleboost, rtcosic and MattH like this.
  9. Carl Wilson Member

    Messages:
    1,357
    Location:
    Moray
    Very nice repair and very interesting explanation of all the steps involved. I really enjoyed reading about it.
     
    Fazerruss likes this.
  10. addjunkie

    addjunkie Member

    Messages:
    5,176
    Location:
    Northumberland. Reet oot in the sticks
    Nice work, what mill is it, the spindle nose to table is a good size
     
  11. Wallace

    Wallace Member

    Messages:
    6,467
    Location:
    Staines, Middlesex, England.
    :thumbup:
     
  12. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    doubleboost and addjunkie like this.
  13. doggone1 Member

    Messages:
    69
    uk
    Thats a good job youve done there nice mill to
     
  14. Fazerruss

    Fazerruss Member

    Messages:
    2,355
    West Yorkshire
    Thank you. Here is a better pic of my mill.

    20180307_213828.jpg
     
    Last edited: Oct 30, 2019
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