Crack in engine case - can it be repaired?

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  • esolliday
    • Feb 2026
    #1

    Crack in engine case - can it be repaired?

    During the rebuild of my 84 GS1100GKE, I found a crack in the upper engine case where the nose of the countershaft comes out. The crack is between the 'C' clip retainer and the clutch housing (see the picture).
    CrackedFlange.jpg

    Can this be repaired? Does it need to be?
    Tags: None
    • Buffalo Bill
      Forum Guru
      Past Site Supporter
      Super Site Supporter
      • Jun 2008
      • 6006
      • New Buffalo, Michigan 49117
      #2
      I'd weld it

      Not a major stress place, and what do you have to lose having it MIG welded?
      1982 GS1100G-
      1990 GSX750/1127
      1987 Honda CBR600F Hurricane
      1985 Kawasaki GPz750

        Comment

        • Carter Turk
          Forum Sage
          Charter Member
          • May 2002
          • 2282
          • Bellingham Washington
          #3
          Mine cracked off. It was hanging on one side for awhile.

          GS\'s since 1982: 55OMZ, 550ES, 750ET, (2) 1100ET\'s, 1100S, 1150ES. Current ride is an 83 Katana. Wifes bike is an 84 GS 1150ES

            Comment

            • esolliday
              #4
              OK, Thanks Bill.
              I will talk to a guy I know from a local metalwork shop, and have him do it.

              Any idea why that crack would have formed where it did?

                Comment

                • esolliday
                  #5
                  @Carter...I thought mine was bad

                    Comment

                    • chuck hahn
                      Forum LongTimer
                      Past Site Supporter
                      • May 2009
                      • 25918
                      • Norman, Oklahoma
                      #6
                      Take the clip retainer with you so the welder can set it on place as to not collapse the groove during the repair.
                      MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
                      1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

                      NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


                      I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

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                        • esolliday
                          #7
                          Good point...will do.

                            Comment

                            • Carter Turk
                              Forum Sage
                              Charter Member
                              • May 2002
                              • 2282
                              • Bellingham Washington
                              #8
                              Originally posted by esolliday
                              OK, Thanks Bill.
                              I will talk to a guy I know from a local metalwork shop, and have him do it.

                              Any idea why that crack would have formed where it did?
                              I think it had to do fitting the transmission shaft into the cases. I believe wave washers are on the other end of shaft, in board of the bearing, sometimes the c-clip isn't aligned over its groove. Not much aluminum on the other side of the c-ring.
                              GS\'s since 1982: 55OMZ, 550ES, 750ET, (2) 1100ET\'s, 1100S, 1150ES. Current ride is an 83 Katana. Wifes bike is an 84 GS 1150ES

                                Comment

                                • rapidray
                                  Forum Guru
                                  GSResource Superstar
                                  • Oct 2006
                                  • 8195
                                  • So Cal
                                  #9
                                  Originally posted by esolliday
                                  During the rebuild of my 84 GS1100GKE, I found a crack in the upper engine case where the nose of the countershaft comes out. The crack is between the 'C' clip retainer and the clutch housing (see the picture).
                                  [ATTACH=CONFIG]44756[/ATTACH]

                                  Can this be repaired? Does it need to be?
                                  That is a NON issue & a waste of time & money to mess with. You run the chance of distorting the case & causing an oil leak that it doesn't even have.
                                  Ray.

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