Mangled cases

In my on going project KZ1000A2, I've run in to yet another road-block. Geez, at this rate I'll never get it done...

In the interest of more power and reliability, I stripped the motor down. The plan being to ship the crank to Falicon and have it welded, balanced, lightened etc etc. I spoke to them and no probs. Send it along and they'll work their magic. However, getting the cases apart was more trouble than it was worth. 30 years of heat cycles welded one of the case bolts into place and of course I broke it off.

I've gotten good at drilling and re-tapping by now, so whats one more... Nope, drilled it cock-eyed and somehow managed to break off a steel drill bit in there!
I've also managed to mangle the mating surface of the case at this part too.

I've got some cobalt bits and a drill press, so I'm going to give it more try. Hey, if its already trashed, I can't make it worse right?

Should I bother? Or should I just email old kawman today and see if he has a set of cases that'll fit? Would the crank I have fit? I know the case halves and bearing cap are machined as a set and need to be matched.

try not to laugh too hard when you read this...

Any thing can be fixed, it's just that sometimes the price is too steep.

I suggest that another set of cases is in order, so that you can keep your project going forward. I'd put the old cases back as soon to be your back ups. Given a little time you figure out how to make the repair.

KZCSI

take the cases to a machine shop that has a EDM machine, they can burn out the bit and the bolt, plus if the case is messed up they can weld it and machine it down.

a cobalt bit is not going to drill out a drill bit

BSKZ650 wrote:

take the cases to a machine shop that has a EDM machine, they can burn out the bit and the bolt, plus if the case is messed up they can weld it and machine it down.

a cobalt bit is not going to drill out a drill bit

Your right, it won't! (Ask me how I know...)

To both of the previous posts, thanks for the sober second thoughts. Always good advice here.

Sam

got a picture of the case?

I would do like BSKZ650 say's. An EDM shop will be the best way to get the drill out. The drill is made of HSS(high speed steel) and about the only way to machine it out would be with something harder than HSS so that means you would use carbide tooling or burn it out with an EDM machine. This happens more than you think and these shops are used to getting broken tooling out and it shouldn't be too much of a problem.

Good luck!

KZCSI wrote:

Any thing can be fixed, it's just that sometimes the price is too steep.

I suggest that another set of cases is in order, so that you can keep your project going forward. I'd put the old cases back as soon to be your back ups. Given a little time you figure out how to make the repair.

KZCSI

this is what i would do...cases can be had for a reasonable price on ebay. just my 2 cents worth. either way, good luck!

Perhaps already considered the options mentioned in the following link, but if not, here it is again.


alum

I have a good case available, from a 80 KZ1000.
I just toOk it apart for the crank, which I needed in my 82 KZ1100.
Make an offer, fair to both of us.

I know a guy with cases that would offer you a good deal. If you're interested, PM me.

Larry C

If you get a set of replacement cases that are '79 or later, be sure to get the transmission shifter cover too.
The '73 - '78 cover is different from the '79 and later although most other parts will interchange. Don't ask how I know!$$$!:pinch:

knackerman wrote:

If you get a set of replacement cases that are '79 or later, be sure to get the transmission shifter cover too.
The '73 - '78 cover is different from the '79 and later although most other parts will interchange. Don't ask how I know!$$$!:pinch:

cant you just swap the trap door that the cover bolts to and mount the other style cover?