Clutch Broken Clutch, Please help.

Discussion in 'Transmission / Drivetrain' started by coexist123, Aug 16, 2011.

  1. coexist123

    coexist123 New Member

    So my clutch broke the other night, the chain jumped of the rail and slammed into it cracking a piece on my bottom end, and my clutch cover.
    Highly upsetting.
    I've tried J.b weld, but its not strong enough to hold the pressure of the clutch.
    any Ideas? or am I stuck with buying a whole new bottom end?
    Pictures are attatched

    Attached Files:

  2. Al.Fisherman

    Al.Fisherman Active Member

    Just another case that JB Weld really doesn't have a place on a HT...Don't get me wrong, there are a few applications, but very few.
    Truthfully, it's not worth fixing if you want it to look good. Buy another one from a vendor or a member.
  3. coexist123

    coexist123 New Member

    Looks aren't initially what I'm going for. Haha.
    I'd just like it to work.
  4. retromike3

    retromike3 Member

    buy a new cover or..

    I would look to see if you can pick up a new cover. Otherwise I would look up a fabricator and see if he could weld that piece back on.

  5. coexist123

    coexist123 New Member

    The cover would be easy to replace, but Without being able to use that third screw the cover wouldnt stay in place. and the clutch would still be useless
  6. retromike3

    retromike3 Member


    looks like you need to have that case fixed. I had a similar problem with the mounting hardware. The engine case broke right were you mount it to the frame. I tried to re-drill and tap new mounts but, It just failed. So I was out eighty bucks and got out a new engine.(I bought it when it went on sale for cheep a year earlier). I am now running without a replacement engine(fingers crossed)

    The next question is weather the price you would pay to get the block tacked back together more or less than the price of a new lower end. To add to that is the question of weather the new block you buy is the same set up as the one you had to begin with? I have had three engines and they were all slightly different. They almost matched, even if you get it from the same supplier there is no guarantee so you might as well get the whole motor. I am thinking about a hundred US. dollars without any other parts.

  7. IbedaYank

    IbedaYank Member

    case is $22 cover $7
    pro welder that can tig weld aluminum $45 to 125 an hour prolly couple hours all said and done worth of work IF the crappy cast **** can even be welded

    now how much is it worth to you???
  8. Big Red

    Big Red Active Member

    Engine casing and cover

    Hey Coexist123,
    Where are you? I run a small Motorbike build/repair shop so I've got a few good used bottom end casings and gear/clutch lever housings. You pay for shipping and they are yours. I can't say for sure they will fit only because of chinese "quality control" but they should fit just fine. If you want them, let me know and I'll seperate the casing's and put it aside with the lever housing for shipping ASAP. I might also have a case gasket. If I do I'll throw it in too. That is really the only way to fix this. JB WELD? Only to glue a new emblem somewhere on your bike, or something that ain't critical. Pretty much every part of the bike is critical and I would'nt trust it on MY bike. Perhaps for a temporary emergency repair, Never for something I wanted to last for more than a few miles.
    Anyway, LMN what ya wanna do.
    Big Red.
    PS. Keep that chain straight and adjusted properly. A friend of mine did ALMOST the same thing, But only the clutch lever housing got broke. The chain can "bunch up" on the gear.
    Last edited: Aug 16, 2011
  9. blue 48

    blue 48 Member

    :(oh man thats a bummer sorry to hear about your bad luck hope your up and running soon
  10. HeadSmess

    HeadSmess Well-Known Member

    there is a "solder" for alloy, thats basically welding... used it before, needs an oxy torch or good mapp gas or whatever that stuff is... and some skill too, i admit...

    something called versaweld or technoweld or something... i believe its mainly composed of zinc in fact...

    been there, done that, that is one weak spot there, behind the sprocket...

    oh! and, if you can use an arc/stick welder...theres alloy filler rods available. fleabay etc... never tried em...i bought a tig instead :D
    Last edited: Aug 18, 2011
  11. IbedaYank

    IbedaYank Member

    the brazing type rods will cost more than buying a new case

    alloy arc rods need a dc capable welder and are best on over 1/4 inch or they just blow through it and takes some hood time to run them so the welds are good

    Then there is the alloy that the cases are made of and the gas and oil that contaminates the cases making welding challenging even using TIG welding
  12. FelipeCobu

    FelipeCobu Member

    HTS 2000 is another of those aluminium repair rods, but otherwise the publicity it not that easy and require some skills to use.

    The problem using electrodes for aluminium is they melt because humidity so rarely you can buy it alone, just in closed packs. I don't know there in US but here im Brazil they are quite expensive too.

    Other problem the heat can warp the case really easy.
  13. HeadSmess

    HeadSmess Well-Known Member

    yeah, ok, the rods i got cost me $100 or so for a 5 kg pack... and i basically use them with hydrochloric acid for making flux for normal lead/tin solder... :eek: or to make zinc chloride in other words. in other words, you will use whatever rods you buy to fix other things, or for other uses altogether... i use my alloy tig rods for anything but welding!

    humidity/ damp electrode coating is easily fixed with a griller, oven or any other source of gentle heat :) as i say though, never tried alloy rods, and if theyre anything like stainless rods....:eek:

    the problem i found with the heat was it set the grease in the bearing on fire... lol. but the cracks easily cleaned with unmixed petrol, then a rinse with acetone, and a slight grind to get rid of surface contaminants...welded nicer than some extrusions ive tried welding before... lets say the case was a bit warped from the accident that caused the crack

    but fiiiinnne! get a new case :rolleyes7:easier....except then you have to split the bleeding engine :) and my attitude with these things is its easier getting a new engine once the cases need splitting... :D the three hours work is (at standard shop rates) about 225 dollars...
  14. retromike3

    retromike3 Member

    replacement or repair.

    Good point I am on my third engine now at three years.

    First one: ate a piston spring clip and seized up.

    Second one: the motor mount bolt broke and after I replaced it with a stronger type of steel the case broke.(bad design in my part, had a problem with a too big seat tube)

    Third one: going OK so far. went with a big tube adapter from Sick Bike Parts and a tuned pipe from the same. Makes me feel really slow on my other(pedal) bikes though.

    I think there is a point of diminishing returns on these machines because they are so inexpensive to buy that its cheaper to replace them than to fix them.

    I did wind up using the carburetor from the first engine and the CDI from the second one. I have basically stripped the old engines down to parts and stocked everything in bags and boxes "just in case".

  15. IbedaYank

    IbedaYank Member

    had some of the chrome come off the cylinder and it ate the piston.
    cost of parts $52.00 after shipping was added
    **** for a regular cycle i can't even get just a piston for that
    that was piston rings gaskets and the jug
    these ht motors are so simple and easy to tear down anyone with some motor knowlege can do it and do it correctly
  16. coexist123

    coexist123 New Member

    Ibeda! Where are you finding this price? Please send me a link.
  17. coexist123

    coexist123 New Member

    Hey big red!
    How much were you wanting to let go of those parts for?
  18. IbedaYank

    IbedaYank Member

    or boygofast on ebay has them for $17.50 plus shipping thats the cases

    clutch cover is $7.00 at gasbike $5 at boygo fast
    and ordered some parts from each.. boygofast parts got here to middle TN 4 days sooner