Just seen this, should be no problem getting a repair on that, seen far worse fixed up. Glad your not hurt, broken chains are a frightening thing. I remember a friend of mine on a GPz being bowled down the road when his back wheel locked up at a fair spin . He was very lucky to come out of it with some nasty hand skin removal after his gloves had taken the brunt of the macadam and his back side was a nice site too. The bike was in bits.
I asked a very experienced ally welder if he could do it without stripping the engine and he was convinced that the area being welded inside and out needed to be spotless. Sooo I'm splitting the crank and taking the bottom half for welding (lots of work but a permanent fix) I'm reading up on it but would like some clarification from someone in the know whether i can skip out any steps as I just need the bottom half off: Remove Engine Valve cover off Remove Cam chain tensioner Remove camshafts and follower Remove Cam chain & guide Cylinder head off (valves are within the head and no need to further disassemble?) Remove cylinder liners and pistons (special tool required) - not clear from haynes the best method of doing this...it says if the crankcases are being split then do this now...its cyclic both sections refer to each other rarggh It does say if the crack cases are being split just for inspection of the crankshaft then you can miss most of the steps 3-7 above...will I get away with this? bearing in mind I am taking the bottom off? Remove alternator and starter clutch Remove clutch Remove starter motor Remove sump and pipes Remove Oil/water pump Finally separate Sorry if this is all very obvious. Let me know what I may be able to skip and what I won't be able to...think the only bit not clear for me atm is the points 7/8 above.
Maybe now its out i'll take the sump off and see if I cant clean thoroughly both sides for a weld fix without disassembly! That'd be a treat if it's possible!
With the sprocket off and an air dremel managed to clean the area up pretty well for welding. Took it along to this nice chap who wouldn't take my money off me. Will take a pic of the fix later but he's done a good job considering it was tricky to get at. The hole was actually over the parting line between the upper/lower crank cases so I dont think taking it apart would have been a good idea anyway. Fingers crossed I remember where all the wires go!
Anyway all back together and fired up first time with an engine light. I've had this before and it just went out after a few rides! Rode it home and it was running sweet (better than when I bought it), stopped for petrol then wouldn't start again! Ran the battery flat trying to get it going...was starting but not running smoothly, like the timing was out and as soon as I came off the throttle it wouldn't idle. I'm thinking something in the ecu? The camshaft and master sprocket were 100% correct Had to push her home 2 miles with a pretty steep hill to finish ha! Just glad to have it back together, hopefully this is nothing big...
Started fine this morning and ran sweet, drove it to the garage as i wanted it plugged into a pc to see what's going on & sure enough turned it off and wouldn't start again! Hopefully not too expensive.
Cheap as chips, dropped it at garage then something clicked. Forgot to re-connect the Airbox pressure pipe...at least I think thats what it was.... the pipe which fits onto this fella here: http://thumbs1.ebaystatic.com/d/l225/m/mapS4hD4PRFjJO_JpUK6VvA.jpg Sorted and been riding for a few weeks without issue
