stress crack in shifter boss

Hi, I had the trans door off my motor today and the boss where the shift shaft slides into has a stress crack.

I have had this to happen before on a 77 kz1000 now my MKII has one. I have never had this happen on a kz900 case.

Is this common with the 1000 cases? I had the crank welded and the block bored with a main bearing cap support and a billet 2nd gear last year and all was good to go.I ran it with the stock top end and over the winter went with 1105 kit with cams and now this.

Do any of you guys know of a way to fix it without tearing the motor back down?

Is this on the outer engine case cover or inside by the countershaft sprocket? I'd image any good welding shop could repair it.

It's on the inside behind the trans door on the engine case itself

sounds like those set of cases must have broken a drive chain at one time is it just a crack or is actually broken. because if it's just cracked you should be ale to get it welded right in the bike just becareful with dirt and slag.

It's just a crack where the shift shaft slides in.

try getting somebody to weld it up i've had that happen before my self a few times in fact when i've broken a chain drag racing happens some times.it not a precsion piece it is just more or less a guide anyway.

Thanks I will do that. You think if I had of put a brass bushing over it before it cracked it woulda helped any? Also is their 2 different sizes of over shift bushings for the MKII"s

no and all that over shift bushing does is prevent the shifter mechanism from trying to rotate around when it's air shifted.

Ok, I have a air shifter with a O.S. bushing.. Was thinking maybe I had the wrong bushing and caused it to crack. Hey tell me where the bushing go's please

I found a welding shop and they told me MAYBE but to bring the bike to the shop and they would take a look. 100 mile one way trip so I hope it's a good return trip. What do you guys Think tig or mig would be the best for this repair?

tig for sure if you can get at it...but mig will do....be careful to put the ground as close to the weld as possible or you run the risk of arcing across the bearings...also unplg any electronic ignition pieces...good luck

as ben said make sure that you unhook your ground strap and just to be on the safe side disable all your electronics so's they won't get fried and that is very good advice that anybody planning on getting any welding done attach the ground as close as humanly possible electrical current going thru roller bearings causes a condition called false brinneling basicly what that is are flat spots that are formedon the races and on the roller it self.