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Discussion Starter · #1 ·
So where the Starter Clutch Idler Gear sits, the tube insert broke. I know one of my options is to get the part welded.
My question is if anyone knows if it's possible to swap the lower block for the k3/k4 block? Would anyone happen to know if swapping the internals is possible?

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Likes to race old junk.
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You can't just change the lower case because the upper and lower are line bored together for the crank...they are a matched set.
There are titanium sleeves available to prevent this kind of damage.
It's tricky to repair this, find a specialist...it often ends with a search for another set of cases.
 

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"swap the lower block for the k3/k4 block"
Either I don't understand what you're saying or you don't understand the crankcase construction. The crankcase has three sections, not two, that are machined as a matched set. The junction between the upper and middle is critical as that's where the split for the crankshaft is. The boss that broke is in the upper. So you're stuck with either getting a new crankcase, repairing yours, or push starting the bike. The junction between the middle and lower is where the transmission shafts are. It's not a good idea but people occasionally replace the lower. They get away with it (sometimes) because the shafts run in ball or roller bearings with strong outer races.

There are epoxies from companies like Devcon and Belzona that might allow a repair to be made, particularly if you have the chunks that broke off. It's a crapshoot but you might want to give it a try. Preparing the aluminum so that the epoxy adheres well is probably critical.
 
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