Hey guys, I need IMMEDIATE HELP. I went down today and the lower case is cracked (the lower fairing screw split it). I have a cracked oil pan too. Is this something that can be welded or do I need to replace the lower case??

I was SUPPOSED to be going to Laguna for a track day in a week! :cryin

I need help PLEASE! Assuming I can get the parts, can someone give me some pointers?

Cheers!

I dont think they will let you on the track with a welded cranckase, better get new stuff, I m sure you could get sidecases from the aftermarket for less than yamah. bummer..:(

The actual covers came out okay, it's the lower case that is cracked :( It got clipped by a guy in a mercedes so the fairing got twisted, breaking the bolts that attach to the oil pan. The thing is, it twisted so much it broke the lower case :cryin

How about a couple pictures to see the amount of damage to the items.

I just did my transmission(removed lower case) and the biggest thing that helped me was having the Yamaha tech manual(not the owners manual). I took the motor out, tranny repair, and reassemble. The bike fired up right away and all was well except one cable routing:D
The book helped a lot, and it was cheap.
Include it on your parts order, and good luck.
If you get the parts soon, you might make your track day.

welding would bee your best option. You can't replace only the lower case. The upper and lower case are matched you would have to buy the set. retail $1200. I just got into an accident. A guy on another bike pulled out in front of me. His footpeg went into the side of my engine where the sight glass is. I am getting it welded. should work perfect. good luck

Originally posted by Canuck
I just did my transmission(removed lower case) and the biggest thing that helped me was having the Yamaha tech manual(not the owners manual). I took the motor out, tranny repair, and reassemble. The bike fired up right away and all was well except one cable routing:D
The book helped a lot, and it was cheap.
Include it on your parts order, and good luck.
If you get the parts soon, you might make your track day.

When you say the "Yamaha Tech Manual", are you referring to the Yamaha Factory Service Manual? If so, you can download the entire manual from this website. Just run a search for "manual"

Thanks guys. I have the service manual (hard copy and .pdf).

Really? You have to buy BOTH upper AND LOWER case??? That's crazy!

I have pictures coming in about an hour so (gotta develop and scan them) so I can show you all the damage :(

I'm still pissed about it. I usually haul ass up those roads and the bike is always rock solid. I don't know what the hell happened today... perhaps she was leaking oil onto the rear tire. Something was definitely up. I really want to find out what it was so I can correct it :confused:

Thanks fellas.

If it twisted the oil pan hard enough to crack it and the lower case I'd go with new parts cause that aluminum has been stressed to much. It might hold at first but under running hard on the track it may give way somewhere else and that could be bad news at speed. And make sure while your in there to give the internals a good once over for stress cracks, don't want things coming apart inside.

I am still not exactly sure what is damaged. If it's just the oil pan then either get a used one or weld the old one. If it is the case, you will have to replace the case. Anything less is a TEMPORARY fix at best. The cases are sold as a matched pair because they are bored together. The crank bearing surfaces are half on one side and half on the other. If you mixed and matched it would be a big problem.

If you pay this out of pocket then it will be cheaper to buy a used motor. Getting a new set of cases = a complete motor rebuild. That will be expensive. Aside from the $1100-1200 for the case set the crank bearing's are $100. Plus you will need every gasket and every seal. Just something to think about.

Oh good god!!! :cryin This SUCKS!!!!

Well, here are some pics... take a look and see what you think. If there was a way this could be repaired I would appreciate the advice, otherwise, I don't know what to do :(

here:

here :(

Oh yeah, and another thing, I haven't contacted my insurance about this one. I had an accident in Jan of '01 and they raised my rates a lot since then. Combine that with a ticket or two and all the recent losses the insurance companies have been taking = perhaps dropped coverage if I try and claim :eek:

But if I need the following:

1). Motor (or upper/lower cases + oil pan)
2). Attack rearset brake lever + peg.
3). Brake lever.

And the following to get her back to perfect:
1). Both lowers.
2). Upper fairing.
3). Tail piece.
4). Rear rim (a little scuffed on the lip which I wouldn't fix if I had to pay)
5). Maybe a tank if I was very anal.

What do you think? God this sucks bad *sigh*

Cheers fellas, appreciate the help.

If that is all that is wrong, the small corner piece missing you will be fine. That could be welded up by a good fabricator. If there are any long cracks going up from the missing piece That would be bad. We have had worse than that repaired at our shop. Alot of crashed bike will break the engine cover off, and take a few pieces of the case with it when the bolts are ripped out. We have that kind of stuff repaired all the time. You just need to get out the phone book and find a good fabrication shop. Good luck.

Jay, that is almost it... there is a crack which didn't come out on the pic very well. From the pic you can see the arrow. The crack goes through the threads of one of the bolts and up and to the right (maybe 2" in total). Do you think they could weld that?

Thanks man!

I don't think that would be a problem. If you lived here I could have it fixed for you in about a week. Thats pretty common for one or a few of the bolt's to break the case.

Jay! Good news man! I found a welder in town that can do it. He says it should be as strong as new... what dou you think? Could there be other hairline cracks in there?

Now I just need to find a new oil pan and gasket and I think we might still be business for track :)

Still not sure how I went down. It caught me totally off-guard.

Do you think I need to do a couple of oil changes to get all the crap out of there?

Cheers mate!

The weld will be stronger than any other part of the case. If it were me I would go buy a couple gallons of diesel fuel and once he is done with it I would slowly pour the two gallons of diesel fuel through it, with the oil drain plug removed of course. that will help to pull out any metal shavings out of the motor. Then just add fresh oil and filter and all is good. if you are still worried than put a 1,000 miles on it and change the oil and filter again.

After you run the diesel through it and let it drain for awhile (20minutes) I would add the fresh oil and filter and unplug the ignition coils, then I would turn the motor over until the oil light went out. The plug the coils back up and fire it up.

Jay, thanks for all the help man. Looks like I am still going to Laguna :jump .

Thanks to everyone that contributed to this, you guys :rock