chain hole in crankcase....
 

my 1vj threw its chain last night and in the process cut a slot in the crankcase. anyone know if this hole leads directly into the engine? (theres been no oil leakage) also, has anyone done a reliable fix without stripping the engine etc? cheers.

Couple ways to go:
1. You could pull the side cover off, clean and have the hole Tig or Mig welded. Grind and sand down, reinstall with new gasket.

2. You could clean it up as it sits if you have room to work. Remove Sprocket cover, sprocket and anything else that is in your way. (clean using MEK or other clean spirit).

Now rough up area in and around the hole using emery cloth or light filing. (careful) No oil or oil residue can be present. Must be CLEAN!

Carefully fill hole with JB Weld (I like the two part type) or other permanent Expoxy type products. They are super strong, permanent fix products.

Maybe do two applications. First just to fill basic hole. Wait 24 hours, now fill in completely. Wait 24 hours. Sand down neatly to match surface. That's it.

JB Weld is extremely strong and durable. Resists heat, oil, vibration really well. Basically a permanent fix.

Good luck! :thumbup1:

The best thing to do is remove the case and have it welded. Have a look on ebay for a replacement case. You might get a bargin.

For the time being,

Halfords sell "Hard and fast".. Its a tube of metal epoxy. You mix it to form a putty and fill the hole. £5

As MickyD says, its practically a permanent repair.. (should be in everyones tool kit)

You say it doesnt leak oil. Take it for a proper spin and find out if you're only checking it on idle. You need to get the pressure up and the oil hot to find out properly...

You never know, the hole could effect crankcase pressure meaning your oil isnt being pumped around as efficiently as possible...

Whatever you do, don't leave it !!

The chain snapped on my partners DRZ last year, dumped its oil. Hole was 25mm tall by 5mm wide & located on the vertical clutch arm housing in front of the sprocket. I cleaned out everything I could before filing a small piece of 2,5mm thick aluminium to shape, laying the bike on it's side & having a mated TiG weld over the lot - worked a treat.

I ran it a few times & changed the oil & filter twice more before riding it on the road. Wasn't worth taking it apart as it was an older bike with 20,000 miles on the clocks & the hole was in the left hand crankcase, even doing the work myself, gaskets, bearings & a used case would have equalled a fair percentage of the bike's value.

It's still going strong.

You'd be surprised you know.. I just bought 80% of a DRZ engine for £79 on ebay. Everything bar the cases. Lucky yes, but it does happen..

I kinda regret paying £80 just for 4 Weisco valves from the US now :(