My 1100 sporty cases were "hardness" tested and I was told they were not repairable due to loss of hardness. Surfing the net I saw where cases can be re-hardened by a specific process. (I've found that I CAN'T get aftermarket or original cases anywhere. Please prove me wrong) Is it expensive for this to be done? Also, after 86 1100 cases fit. Legit or what?
hi, grab a picture of the damage it might be a small repair or a big repair ? if its not cracked around any of the shaft bosses it should not be too bad, have repaired a lot of cases esp sporty g/boxes & EVBT behind the lifter blocks , this guy only repairs aircraft engine cases & cyl heads thats all they do they send them from USA to him for repairs if its good enough for areo engines it should be good enough for your sporty it depends where the crack is of course , cheers
Thanks matey, I'll get to mackay (1 and 1/2 hrs ride from here) where the motor is at and take some pics and post em up. Sounds promising in what you say. The photo's will sort it all out once and for all.
Philthy mate reclaim the cases and send em somewhere else mate these jokers dont know what they are doing. if they are doing welded up bosses or reclaiming gravel rash they are scared of having a go of a large repair there are tricks you need to know ie preheating then weld and then slow down the heat draw from the weld ie post heat treatment.
Bruce
hi is that just the boss for the sprocket cover or is that the boss for the foot peg ? i think its just the boss for the sprocket cover that you don't realy need ? there looks like 3 ways around this either weld back a boss & or machine a flat spot that area & thread, with & alluminiun spacer threaded in place or just blank it off if its just a sprocket cover boss that been broken off from the rear chain either sprocket too big or the chain broke ? looks & easy repair no damage else where ? cracks etc 1 st you would check cases for flatness. cheers the sprocket cover has 2 or 3 other bolts holding it in place ?
The bottom pic is the broken crank end, apparently replaceable on earlier models but not these? I have to draw the line at how much I want to spend,another crank =$$$"s.! The bloke at the shop is having a bigger sniff around at finding more cases/bottom end and whatever to sort this job out. He's come to believe that I'm serious about this project. It's not that their screwing me around,it's just not their expertise in welding and machining cases. They get that sort of job done outside,fair enough. They've done the right thing by me so far,been very good. Not many shops take you out into their workshop area and talk harleys for 1/2 hr. He's actually got a nitrous sporty he drags and gets times in the 10sec range,she fast one matey!! The owner works the shop and genuinely is into harleys.I sure as hell hope it continues that way, mainly because I've got a long way to go to find another NON-HD DEALER shop.
Philthy mate i would not have believed it unless i seen it. at least we now know that the crank snapped
Thats a leg outa bed damage mate to take out the centre of the cases like that.
I will talk it over with a mate and get back to you about the repair cenario and a likely budget cost mate but before you go any further is it still at the shop? or with you because a die penatrant kit to check for cracking around the crankcase mouths and main journals mounts is a must do before you go any further.
Repairing the damage that we can see by the pics (well done by the way) is one thing but that motor has sustained some serious damage it is salvagable but at what cost ?
at least at the moment there is about 4 pillars to repair as daddyracer suggested spotface drill and tap cases and weld inserts in.
Then there is the mouth weld, machine crankcase joint line, assemble then bore mouths and then face deck of cases.
Get back to you soon mate
Yes mate they busted it good
It's still at the shop. I'll wait and see what he can come up with in the next few days. My missus is going down to Nowra (NSW Sth coast) tomorrow and there is a set of cases/half a motor, bits and pieces, (not 1100) there that the guy here is making enquiries about, so if it works out, she can bring em home. Won't she get pissed off lugging 50 or more kg's of motor home on the plane? The guy at the shop here will do the liasing with them,he know's mechanical jargon. What fits what and the like. Could come up with a less expensive scenariou. I appreciate you getting a quote for me Bruce,that'd be great. More soon,stay tuned.
the 4spd evo sporty 1986 to 1990 is known the break the pinion shaft off because there is no radius on the shaft the shaft is part of the flywheel & can be repaired by machining a taper into the crank flywheel & putting a S&S pinion shaft into it but is a complete crank rebuild + machining work , the gearbox suffers the same as the countershaft has no radius & can break & push through the bottom g/box case with bad damage to the cases , g/box countershaft is replaced by the earlier 1952 to 1983 countershaft even by the factory they no longer make the later 4 spd shaft ,1st gear is also replaced back to early as it all fits up with no modifications , i only seen the 1st photo but the other damage is very repairable if you get stuck on repairs give me & email , but buy the time you finished it might be as well too buy a 5 spd 1991 up motor these are very strong, the 1st EVO's sporties were 1 of the weakest models made esp the clutch hub with the alt in behind it with only a c'clip holding the hole basket on but if you realy love that bike you can fix it up strong enough we have repaired cases damaged more than this , good luck with her if you need any info feel free to ask as i've been around sporties for more than 30years if i can help with any questions on early sporties
As per Daddy racers comments which is an excellent discourse in what can go wrong with those early evos which by the way almost word for word was relayed to me by my mate, Philthy you are up for some big bucks to repair those cases and crank shaft alone mate.
Yes they can be repaired but paying the going rate including maching is in the ball park of about about 1200 to 1800 he was very concearned that to knock out the centre of the case like that the mains Will have bell mouthed and there will be fractures around them.
His words to me where to chase down a latter 1200 motor mate its not what you want to hear i know but they toasted that motor good.
CASES WELDED & MACHINED, JOBS DONE.
Getting there. Just gotta sort out a front end,rear shocks etc etc etc. Put the bike together mock up,then pull to bits and refine the whole job. I'm happy with being able to get the original cases repaired,didn't think it was possible at first. This job cost $825. Worth every cent. I want to keep the motor as stock as possible,or maybe warmed up but not "hot'.
