Torn reduction gear hole

One thing I have not seen said about is DO NOT buy just a top case half.
If you buy a case get a match'd set.
The case's are line bore'd for the tranny also.

zukdave wrote: One thing I have not seen said about is DO NOT buy just a top case half.
If you buy a case get a match'd set.
The case's are line bore'd for the tranny also.

Would you believe I saw at least two different vendors on ebay selling case halves individually??? Honestly I don't have that much experience with engines, but even I can figure out what line-boring means and see that every case is going to be unique. And these vendors are doing a huge disservice by leading people to believe they can save $50 getting only the case half they need. Definitely a good warning to have out there for anyone else needing to swap cases.

@daveo: You're assuming I have a machine shop handy to make these modifications. You also made me realize that I hadn't checked the stator cover to see if the gear pin was supported from both side... It is, and the hole inside the stator cover is damaged as well. There is also material built up inside each hole, on one side, like something got jammed up and they continued to run the bike. Regardless, this doesn't look like something I can just patch-and-go. Something bad happened, and I need to figure out what before I try starting it up again.

Sorry to hear about the problem with your motor. But you do have the right attitude...
Get-er-done, boy!

What zukdave said is totally correct, cases and cap are line bored for crank and tranny as a matched set only. Believe me I have learned the hard way with some sellers who knew better and who sold me stuff that was so wrong because I was at the start of the learning curve....something I will never do in return.

You will probably not have to replace crank bearings....if you do it's likely the internal bearings are shot too and those are press fit in so maybe a "new" crank would be in order. One good thing about getting a new set of cases is that by rebuilding them yourself you will know exactly what is in there with no further surprises. Do you have a factory service manual? If not I would encourage you to get one for the rebuild. Keep a log and post with some pictures....everyone loves those pics, looking forward to seeing what you do.

Check your starter clutch. If it has any broken spring pieces, it may hang it engaged. It could be the source of the damage.

bluezbike -- I did find a pdf of the service manual, haven't had much time to go through that yet. I have every intention of doing a full tear-down and rebuild, because I want to know the bike inside&out.

Motor Head -- You know, that occurred to me too, something hung up and kept the starter engaged. I'll have to tear deeper into the engine to see what's happened. Unfortunately I wrenched my back badly earlier this week, and just getting back to where I can walk without much pain. I hate it when age gets in the way of having fun!!!