I broke my oil pan at the plug thread

I agree I'd be constantly wondering about it so much I couldn't even enjoy the ride.

Thanks again for all the advise so far!

For those who missed it, this is my first time working on or (barely getting to do) riding on a motorcycle.

Where do I want to separate for the shop?
He alluded to potential size issues and I also wonder if weight could be a problem (although I suspect not).


I'm guessing #3 is best but I wanted to verify its feasibility first

Your really opening up a can of worms taking the head and barrels off if your a newby plus the cost......... wonder if you could just remove the tank, seat, drain the carbs and probably the brake fluid an have him, you and a friend gently lay it on its side for the repair..... if not maybe just pull the motor and have a friend help with the lifting and flipping ??

I wouldn't break down the engine.
Steve

ccpete wrote: if it is designed to take the place of a plug won't it still leak through the place where I have no thread in the case?

Not if you JB Weld it in place... and JB Weld the broken piece in place, to fill the void. I suspect you could seal it up enough to ride with. It's not a race bike! :whistle:

So if I understand correctly #1 is a bad option, because a lot is involved in breaking down the engine.

What about #2 at the carbs? Probably a good time replace carb gaskets too since they look worn?
(I think I may have a vacuum problem as well, but I haven't been able to get the idle steady enough to check)

I could pull and buck that engine around myself. When you take it to the shop you can paint the frame while you're waiting.
Steve

Before I even contemplated removing the engine I first would find a shop who could perform the repair. It is very likely they will be able to do it with the engine in the frame; in fact, they may prefer that. If they can weld it with the engine in the frame just be sure to remove the battery and drain or remove other things that contain fluid if they plan to lean the bike on its side. You may be ok not draining brake fluid, but check on that. If you do drain it you will need to refill with fresh brake fluid and bleed the brake which might be a very good idea regardless. The shop may even decide just to put the bike up on a lift to weld it; this would be the simplest way to do it if they can and no fluids would need to be drained. You might be surprised at how well some welders can work in difficult positions.

Regarding the carb holders (the rubber things between the carbs and cylinder head) before you loosen or try to remove them FIRST find a set of replacements. That may prove to be difficult depending on your model bike, so you don't want to mess up the existing carb holders if replacements are not available.
Ed

The welding shop I talked to is quoting me at $100 - $150. Is that normal, or is that a please-go-away (extra high) quote...?

Myself? that is way cheeper than striping head barrels gaskets,time or buying a replacement motor.Of which you may be dollars ahead anyway and keep the$$ or spend the money and have it run for ever or not. If you weld and tap there will probably always be a drip at the bolt head mating surfaces and O ring. unless youre verry very good with a file.

What are they doing ? Are they going to weld . Tap out the threads and put the plug in send it back to you fixed or is that just welding the hole and you have to do the rest .If they are going to give it back done and you can move on with the project . I think its not a bad price . Can they do it with the motor in the bike or do you have to pull it . Are you sure the motor is good ? Have you got it up and running ?I would at least do a compression check if you haven't just to know what you have before you keep throwing money at it .

If a shop tells you they can weld that without splitting the case they're full
of shit. You CAN NOT WELD IT WITH OIL RUNNING OUT OF IT.

Go read my drag strip thread and you will see where I hung my oil filter bolt on the trailer
edge and ripped the oil filter mounting boss filter and all out of the case and what it took to fix it.
IMHO your best bet would be find a motor or find a new bike as I'm not sure you have the know how to fix it right.

Oh by the way that rubber washer go's on the oil filter inside the cover.