Thank you I appreciate that. Thank you for taking the time to watch. Mike

Mike I have a KX250 case that needs that drain plug repair and the boss broke off that holds the pin that brings the shifter back to center. Not tech savvy enough to figure out how to DM you. Thank you, Gene

Sorry, I'm buried for the next several months at least and not taking on any more side work until I get caught up. I appreciate your thinking of me though and thank you for taking the time you watch. Mike

Thank you. I appreciate that. Mike

Thank you for taking the time to watch and comment. Mike

Thank you for the kind words and thank you for taking the time to watch. Mike

Thank you, I appreciate the comments and thank you for watching. Your right, oil soaked cases are not for the novice. 😄 Mike

where are you located and how much to weld a place on a 2002 kx250rt side case i can send you pics if you give me an address

zmotorsportsjkur@gmail.com I don't quote prices because I generally have to see the item as I've gotten burned in the past. I am in northern Utah and did side work when I have time. Thanks. Mike

Thank you. Glad you enjoy the content and thanks for taking the time to watch. Mike

Thank you for watching. Mike

You’re welcome. Thanks for taking the time to watch. Mike

Thank you for the comments and thanks for taking the time to watch. Glad it was helpful. Mike

Thank you. I'm sure he appreciated the repair. I received great feedback on it. I appreciate you taking the time to watch and for the comments. Mike

I appreciate the feedback. Thank you for taking the time to watch and thank you for the comments. Mike

Thanks for the comments and thank you for taking the time to watch. Mike

Thank you. It gets used quite a lot. One of those shop tools that I should have made many years ago. Thank you for watching and commenting. Mike

Thank you. I appreciate you taking the time to watch and I appreciate your comments. Mike

Just follow the process that I outlined and you should be fine if you are familiar with welding aluminum. Also keep in mind that not all cast aluminum is created equal as some have more porosity or less porosity than others so some adjustments on the fly are often required. Good luck in the repair and don't rush it. Thank you for taking the time to watch. Mike

Thank you and thank you for watching. Mike

Thank you. I couldn’t agree more about the details. Thank you for watching. Mike

Thank you. I appreciate that and thanks for taking the time to watch. Mike

Thank you. Mike

Thank you very much. I’m flattered by your comments. Thanks you for taking the time to watch and best of luck in your repair. Mike

Thank you very much for the comments and for subscribing. Glad you enjoy my videos. Mike

Thank you and thanks for watching. Mike

Thank you and thanks for watching. Mike

Thank you Carl. I appreciate that. Mike

Thank you for taking the time to watch. Mike

Thank you. I have a Precision Mathews PM1340GT lathe. I have a full review of it way back in my video library. It was one of my first videos on KZfaq. I also have a review video for my PM935TV milling machine about the same time frame. Thank you for watching. Mike

Thank you for the comments. I have been using Formax F-200 for many years. However, I recently tried CRL Tube Wax and actually prefer that, especially on abrasive discs, but also on rotary bits. Mike

Thank you@@zmotorsports62

Thank you and thanks for taking the time to watch. Mike

Thank you and thanks for taking the time to watch. Mike

Thank you and thanks for watching. Mike

Thanks Quinn. I appreciate you watching. Mike

Thank you. I wish I was a fabricator or a machinist but I’m just a mechanic who’s expanded his skillset a bit. Thanks for watching. Mike

Ya, I enjoyed this thoroughly. Cant believe the dickhead who commented on your choice of words of all things. Why dont we critique his videos...oh nevermind, we cant. Lol great job my man, nice shop!

Thank you. I appreciate you taking the time to watch and especially for the comments. I don’t get some people with their comments but I appreciate your feedback. 🤔 Mike

For many years I used 4043 but the last several years I've been using 4943.

Thank you. Thanks for watching. Mike

Thank you John. I appreciate the kind words. Thank you for taking the time to watch. Mike

Thank you and thanks for watching. Mike

Thank you and thanks for taking the time you watch. Mike

I do take on side jobs when time allows. Thanks for taking the time to watch. Mike

I would be happy to look at it. My email is zmotorsportsjkur@gmail.com Mike

Thank you. On that particular engine case I can't remember if I used 4043 or 4943.

Thank you for the comments and for taking the time you watch. I am glad you found it informative. As for the Formax, it is #200 and the grit that I used on the surface plate was 220-grit. For lube on the surface plate I just used some JB-80 Liquid lubricant. I don't necessarily think the lube matters all that much, the JB-80 was what I had readily available but I do find myself using it quite a bit for things like this. Mike

Personally I have not seen much success using JB Weld. I know a lot of people use it and have heard of mixed success but I have the capabilities to fix it the proper way by welding and machining so I opt to go that route. I've had to remove a lot of JB Weld by the time it comes through my door over the years if that's any indication. Good luck and thank you for taking the time to watch. Mike

@@zmotorsports62 Since I’m young and broke, I figured I’ll try to patch it myself, if I can’t fix it myself I’ll reluctantly send it in somewhere. Thanks for the luck and for the information, you are awesome. Stay safe, Dominic

I completely understand. Mike

Thank you. I appreciate you watching. Mike

I'm sorry, at this time I am buried and I'm not taking on any additional side until I get caught up with what I have already committed to. Thank you for your interest and thanks for taking the time to watch my video. Mike

If the warpage is too severe it may mean the cases are trashed. When lapping cases some material removal is acceptable but too much and it will reduce crankshaft and countershaft endplay creating a rotating assembly that is way too tight. I would suggest a little lapping at a time with test fitment to measure endplay along the way. Mike

That's what I'm afraid of, I bought one case half new from a dealer and the bike had no issues the first couple years and then out of nowhere the transmission failed as I was driving it, I was in fourth about to switch into 5th and there was no fifth gear it was like neutral so I geared back into fourth and tried to go right down to neutral but it wouldn't. It turned out that it ruined the middle shift fork and burned up a gear but after I got a new shift fork and gear I was putting it back together I noticed the warp issue. It doesn't look like a lot of material would need to be shaved off but I'm in a bit of a pickle and need an expert to look at it.@@zmotorsports62

Thank you. Mike

Thank you and thanks for watching. Mike

Too bad the case savers are taken off

Thank you. Sorry, at this time I'm buried with work and don't have time to take on any more right now, but thank you. Mike

You can check the cases' mating surface easy enough with a straight edge and feeler gauges to ensure it is true and flat.

No, the insert is flush with the inside of the case. I also blended it a little with a rotary bit before sending it back to the owner. Thank you for taking the time to watch. Mike

If I wasn't so busy and backlogged for several months maybe. Unfortunately I simply don't have time.

Whenever I repaired a case at the split where the case halves met I used I file like you then when I was within about .020”-.030” I would apply bluing and lap the case halves on my surface plate, but any large flat surface would be sufficient. Best of luck and thanks for watching. Mike

@@zmotorsports62 as I'm not a machinist by trade abd don't have experience with lapping, what kind of sand paper did you use in the video? And what fluid did you lubricate it with?

I used some 220-grit followed by 400-grit wet sandpaper to lap the case half. I used some WD-40 as lubricant if memory serves and move the case in a figure 8 until all bluing was gone.

I am buried at this time but if you're not in a hurry and can accept the shipping charges I would be happy to do it. You can email me at zmotorsportsjkur@gmail.com Thanks. Mike

Thank you. I can't remember what I charged off the top of my head. About a couple hours of work so in the $160-$200 range.

Are you referring to a threaded boss? If so, in those applications UCD machined a new boss roughly the same size as the one cast into the case. Then before cutting the damaged boss off of the case built a small fixture to hold the new boss in the correct position for welding. Cut the damaged boss off and weld the newly machined boss in its place. I hope that is what you were asking. Thanks for taking the time to watch. Mike

It’s possible as long as you could get it clean enough and there aren’t any seals or other rubber/plastic near the weld area that could be damaged. Mike

I do occasionally when I have time. Currently I am quite backed up work though. Thanks. Mike

I have search for one on line but it's a very rare atv and they do not make cases for it anymore. I also used jb weld on mine but it didn't work just like you said

I would be interested in taking a look at it and trying to repair it. My email is zmotorsportsjkur@gmail.com to contact me. Thanks. Mike

Thanks for the comments. Sorry for the delayed response. If you want to post the video I will take a look at it next week when I have time. Thanks for watching. Mike

@@zmotorsports62 Hi Mike, thanks for taking a look! Here is the link kzfaq.info/get/bejne/qchyhLN0v9-ddYk.html Super cool to watch you work, technical, clean, and precise. I used to work in a bronze art foundry back in the day, did a lot of TIG welding on large monuments (not so technical, clean, or precise). Even helped with the MGM lion in Vegas right before I got fired :) I blame the girl. Good stuff amigo.

Thank you. I’m not a big fan of the digital helmets. I realize they have a huge following and are all the rage but I still prefer a fixed lense. I don’t really like tools that require batteries for some reason although I do have a Miller Big Window Elite that my wife bought me about ten years ago but I just use it in tight spaces when I can’t flip my fixed lense helmet easily. I use a #10 gold lense with a clear protective lense in front on both of my fixed helmets and can see very well. I’ve found that the gold lense seems to reflect some of the light back into the work. Thanks for taking the time to watch. Mike

Hi Mike you just continue to impress me with every project I see you do. Great video.

I don't pre-heat. Just prep, clean thoroughly and weld.

Sorry, I don’t give out email or phone openly but I’m on garagejournal.com quite a bit. You could send me a private message through there. Mike

Thank you. No this case was sent to me buy a viewer from back east somewhere. Thanks for watching and for the comments. Mike

I have several other large projects I have to get done but if you’re not in a hurry for it I’d be willing to take a look at it and see if it’s something I could repair. Mike

My email is zmotorsportsjkur@gmail.com

Thank you and thanks for watching. Mike

I do on occasion when I have time. However, I am buried currently. Thanks for taking the time to watch. Mike

No issues as long as you don’t camp out with the welder. There’s plenty of webbing and support in the case plus the aluminum dissipates the heat so quickly it hasn’t been an issue. Although when I was doing a lot of the Yamaha Banshee cases back in the 90’ through 2000’s when they’d lose a chain and blow the countershaft out and wrap the sprocket into the mix, I would bolt the cases to help with keeping the countershaft aligned and running true when welding back together. I also lap the case on the surface plate when complete to ensure a flat sealing surface. Thanks for watching and hope that helps. Mike

Depending on just how bad they're damaged I generally charge $100-$200 as it takes anywhere from 1.5- 2.5 hours to do these.

Sorry, I no longer have my speed shop. I just posted the video showing how to repair these cases. Thank you for your interest and for taking the time to watch. Mike

@@zmotorsports62 Thanks. What you did to fix that, is exactly what I need. If I use JB Weld just to hold me through riding season, does this really screw the machine shop in the repair?

It will add another level of difficulty to the repair so the machine shop may charge additional if it's been gooped with something.

@@zmotorsports62 can I ask what was the cost for the work you did in the video?

I can't remember that one specifically but most take a couple of hours or so. They run in the $200-$250 range normally.

I don't have my business any longer but do an occasional side job as time allows. My email is zmotorsportsjkur@gmail.com Thanks for watching. Mike

A job similar to this would be approx a couple hours so probably in the $150-$200 range. Thanks for watching. Mike.

zmotorsportsjkur@gmail.com

Ok, I just read that you don't do much in repairs since you closed your doors in 2017. Actually I want to do the repairs on my own. I am asking if you could see what I see in the photos, which is, if it's a possible repair or not. That would boost my confidence a ton or bring into reality if its too much to ask for in performing the repairs. I tried searching for a replacement right side case for a 1991 FLHS and always land on pages the want to sell an S&S lower end for $4,500.00

For clarity sake.....by “collar” I mean, the little edge in the outside of the case, that prevents bearing from sliding out.

Thank you for the comments and viewing George. I don’t do much work for clients since closing my business down in 2017. Mike

zmotorsports Oh ok. Apologies, I was thinking the vid was new. BTW:Your work looks great! Thanks Mike.

I am very active on either garagejournal.com or irv2.com where you could send me a private message. I think you can also email me via KZfaq by going to the “about” section and hit contact. Thanks for watching. Mike

Back when I had my business and was doing a lot of powersports work, a repair such as that would be approximately $125-$200 depending on extent of damage. I’ve repaired quite a few over the years where the sprocket on the transmission countershaft came apart and tore the side of the case out. Those required more time and therefore could potentially be upwards of $300+. Thanks for watching. Mike

Yeah, most shops won’t touch such repairs. Thanks for taking the time to watch. Mike

I am very active on garagejournal.com and irv2.comb You could send me a private message on either of those. Thanks for watching. Mike

Thank you for the comments. I am located in Northern Utah. For a repair such as this they run in the $100- $200 range sure to taking about 1.5- 2.5 hours depending on the extent of the damage. That particular case half was only the drain plug and relatively easy so $120. Thanks for watching Mike

Northern Utah.

Please reference back about 6 comments or so as someone asked already. Thanks. Mike

Agreed. Thanks for watching. Mike

I've done a couple now for subscribers but I'm sure shipping costs outweigh finding a good local shop. If you really can't find anyone else and don't mind the cost of shipping plus the repair I guess we could make it happen. Thank you for taking the time to watch and comment. Mike

@@zmotorsports62 awesome, where do I send pictures of the piece needing repair? It’s an inner casing I was told it can be welded and told by others it can’t so I’m not positive but I can send you a few pics of it and even a video to show you the damage

Send them to zmotorsportsjkur@gmail.com and I'll take a look. Thanks. Mike

Sure. It may be a little bit before I can get to it because I'm buried but I can try to fit it in. Mike

@@zmotorsports62 CAN I SEND YOU PICS OF MY CASE SO YOU CAN GIVE ME AN ESTIMATE THANX BY THE WAY WHAT STATE ARE YOU IN IM NEAR ATL GA

I am in Utah. zmotorsportsjkur@gmail.com Thanks. Mike

I don’t have my business any longer but I still do some small projects for people from time to time. The easiest way to contact me is private message through garagejournal.com forum where I am quite active. Mike

Tons of info and examples here. Maybe you should watch the video with your eyes open.

I am quite active on garagejournal.com. You can send me a private message there under username zmotorsports. Mike