Novice-help needed welding crank case

[RussT]

Something like jbweld would do for now, coat bolt in vaseline torque it up then put jbweld on the casting (after a good clean up)and it should set to pattern of thread without sticking so you can still undo the bolt afterwards.
Or maybe just stick some ptfe tape on the threads, will probably stop the leak as it not under pressure, looks from the pic as thought oil is probably leaking along the threads.

 

[Tinbasherdan]

I think ktm crank cases are ally, it's only the outer covers (stator,clutch) that are mag. I did a similar repair on a cbr 600 the other month and it was a mare, ingrained oil and and not the greatest cast. Got it build up in the end but it wasn't fun

 

[Brad93]

I think ktm crank cases are ally, it's only the outer covers (stator,clutch) that are mag. I did a similar repair on a cbr 600 the other month and it was a mare, ingrained oil and and not the greatest cast. Got it build up in the end but it wasn't fun

This is an outer so will be Magnesium

 

[T0rnado69]

Also soaked in oil. you're probably better off using a chemical metal epoxy.

this is what i did with my son's old 125 scooter..... oil leak from the join between the two casing half's.

a garage told me that to take the engine out, split it, clean it and reseal it. rebuild the engine and put it back in.

would be more then the bike was worth.

so i put the scooter up on the bike ramp.

cleaned the area up with degreaser, sanding disc in a dremel then coated it in chemical metal.

refill it with oil. ran the bike up. left it over night and no more oil leak.

 

[Touchdown]

Some real food for thought, thanks. i think the leak is between the cases via the gasket but as the bolt is lowest point thats where it pools. not clear in pic is that area under bolt head is slightly lower so when tightening bolt bends outwards thus too much will break casing completely.
I will drain oil and remove casing. put it on the mill and flatten the area under the bolt head. Coat both sides of gasket with RTV silicone gasket sealer and use a washer under the bolthead to prevent rotational torque. Clean and use some jb weld in the void. once i have acquired a new one i will remove the broken one and try to weld it.

 

[Tinbasherdan]

This is an outer so will be Magnesium

So it is! Sorry, had looked at the picture but still managed to assume it had burst the lug on the crankcase

 

[Seadog]

I think the problem is the seal between the cover and the crankcase, i.e. the silicone sealant has not been applied on the inside edge of the bolt hole. The bolt is not there to provide and oil seal. Take the cover off, clean thoroughly and degrease, then reapply sealant making sure you circle the bolt holes.

 

[Rig Pig]

What about counterbore to just below the damage and epoxy in a steel sleave in?

 

[leadpig]

I'd try these. You can get the Laser version from Machine mart, but they are expensive there or ebay

cheers for that, that will helped me on a awkward job i have planned

 

[Touchdown]

Replacement cover fitted. day saved cover is indeed Magnesium and old and very crispy/friable. whilst i like make do and mend, because I can, I think this is now fit for the bin.
Thanks all for comments/advice i have learnt a good deal for the next task.

 

[DAPPH]

thanks all for coments. just found thread on how to post pix. my android wouldn't let me post from galery or camera??

For your next time .....
Instead of chancing ruining the casing cover perhaps put a stud in the hole , use stud lock to fix it well without the casing cover in place .
First get some circuit board aerosol can spray cleaner to degrease everything & some cotton buds to soak up the difficult to get diluted grease/oil etc .

Slip the cover on , then push in a small ball of " Poundland's finest epoxy filler " around the stud . Having first wrapped a very short length of PTFE tape round the stud to stop the resin sticking in the threads .
Now use a small flat washer to get things pressed in & level & put a nylock nut on the stud . Once the nut is on and almost fully tightened , make a plastic spatula & push /poke the filler in well & give it a nice smooth finish then give the nut the final pinch up & leave it to set for two days . .

 

[addjunkie]

Devcon or belzona would be my choice to fix this......

 

[RichardM]

cover is indeed Magnesium and old and very crispy/friable.

if it is you need to paint it, magnesium doesn't like water vapour.