Chaincase/Frame Cracked

[Macheater]

Sweet! Didn't realize it was a racing application. Very nice job on the new footrest. Its always nice when ya can fab ur own stuff.

 

[yam177]

Sweet! Didn't realize it was a racing application. Very nice job on the new footrest. Its always nice when ya can fab ur own stuff.

I rebuilt the footrest par from the aluminium I cut off the other running boards bent it up and riveted to the side. No one could ever tell its not stock.

We braced a bunch of stuff on the sled. Last year another rider rode the sled we played with a rear IQ skid some

 

[Voda2000]

Well I got the chain case cover off last night and it looks like the damage doesn't extend into the chain so I can get it welded.

The shop manual talks about a special tool for the engine mount bolts. Do I need this to remove them?

 

[yam177]

Well I got the chain case cover off last night and it looks like the damage doesn't extend into the chain so I can get it welded.

The shop manual talks about a special tool for the engine mount bolts. Do I need this to remove them?

I had mine welded once works pretty good. The specil tool can be made with a grinder and a 12 MM socket

 

[Voda2000]

What is the point of this special tool and do I really need it?

 

[yam177]

What is the point of this special tool and do I really need it?

Nothing helps set the tension on the motor mount.

 

[Voda2000]

Wow this is quickly becoming a huge job. I've got to take the jack shaft and reverse assembly right out of the sled now.

 

[Voda2000]

Ok, I got the panel off and it's really not too bad. I think the welding should be a piece of cake.

I did find the heat shield over the exhaust flex joints is in rough shape so I guess i need to replace that. The top looks worse than the bottom. Since heat rises and the gas tank is above I'm going to replace the top but not bother with the bottom.

Also after I disconnected the exhaust from the head I noticed that the "headers" (for lack of a better word) can rotate. Does that mean the exhaust doughnuts are finished? I can't tighten the clamps anymore.

Here's a few photos.

 

[cannondale27]

Nice job!

Yes i believe you are due for the doughnuts.Get the copper ones aftermarket offers.Your shield is actually fairly good but why take a chance.Get new.I did same as you and just replaced top since is much easier and the major concern.Check Flex joints for cracks by looking through them and look for light.Also look at the head pipes to flange which mounts onto motor they can crack there.Before you put the clamps back on grind a little off the bolt spacer so they can tighten more.

 

[Voda2000]

Thanks for the feedback.

I already ordered the stock doughnuts from the dealer this morning. He gave me a good price on them. If I have to them again some time I might get the copper.

I'll check the flex joints, there doesn't look like there is any signs that exhaust has been escaping so they hopefully the are in good shape.

The owner of the dealership that does all of their custom welding is down south bike racing this week and possibly at Daytona next week. So I don't know about the welding on the frame until he gets back.

 

[Voda2000]

Ok finally got back to it today. My first son was born last week so I've been busy with that.

I had the piece welded and it came out great. I've got the pannel bolted back on but I forgot to install the jackshaft at the same time.

I cannot figure out how to install the jackshaft now. The manual indicates that I can angle it and it will drop in. I can't seem to make it work. Does anyone that has removed/installed a jackshaft with reverse in a Phazer have any tips?

Thanks.

 

[BETHEVIPER]

glad to hear you could repair it. I just saw this thread, I had one of those panels as a new takeoff. welding is cheaper. I am surprised you didn't just take the sled to the welding shop instead of removing it.