Kz1000p case crack

What are y'all thoughts on this small crack on the shift shaft boss? Not really sure how that even happened, from what I can tell this engine has been given at least one shade tree rebuild. I know it can be welded, but is it even anything to worry about? Also, the lower engine case to oil pan mating surface looks like it's been dragged across the concrete, does it look fixable? I'm thinking probably a wet stone to clean some of it up and a little extra RTV with the gasket.

My thought is that it cracked due to stress of some sort and will continue to deteriorate if left as is.  Since you have the cases apart it's the best time to fix it.  RE: the oil pan...if it didn't leak before you pulled the pan I would just leave it.  You might also consider filling in the rough spots with some liquid metal.

With cases readily available on eBay I personally would replace it instead of trying to fix it.

I would make a steel sleeve with the shaft boss OD and press fit it with LOCTITE to stiffen the shift shaft boss.
No need to buy a "new" used case with new unkown/hidden damages!

Is there not a seal in that hole?

It's inside the case behind the shifting arm. 

I like the steel sleeve idea. I'm not going to beat on this motorcycle, any reason why it would continue to get worse? Doesnt the outer case cover take most of the forces from shifting?

The transmission cover has a seal. The sprocket cover has two more. The shifter shaft goes through all of them. If the sprocket cover has a sloppy fit the shaft will move around putting side pressure on the inside pivot causing a crack like you have. 
BTW the sprocket cover seals are inside and out act as a bearing as well. It is a tight fit in between them that acts like a bearing also. I've never seen a crack like the one you have and the KZP has linkage so there shouldn't be any lateral pressure like a shift lever would. I'd check all the other things I just talked about before repairing the pivot boss. 
Just a suggestion. 
Steve

SWest wrote:

The transmission cover has a seal. The sprocket cover has two more. The shifter shaft goes through all of them. If the sprocket cover has a sloppy fit the shaft will move around putting side pressure on the inside pivot causing a crack like you have. 
BTW the sprocket cover seals are inside and out act as a bearing as well. It is a tight fit in between them that acts like a bearing also. I've never seen a crack like the one you have and the KZP has linkage so there shouldn't be any lateral pressure like a shift lever would. I'd check all the other things I just talked about before repairing the pivot boss. 
Just a suggestion. 

Steve

They all seem to have their "dark and dirty secrets" in their past life 

I was thinking it was in an accident, repaired then sold. 

I do have a whole another donor engine that I could tear apart and see if the case is any better, but judging by the condition of it I'm pretty sure that's not going to be the case. Its been, shall we say, abused just a tad.

Yikes!  It's going to take some serious work to repair that head!

In reply to your question re: stress transfer....in short, no.  The stress is not taken up in the outer cover.  It's transmitted to the inner cover.