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Old August 6th, 2017, 04:22 PM   #1
ck.mecha
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Name: Chris
Location: Atlanta
Join Date: Nov 2015

Motorcycle(s): 1969 Benelli Cobra 125, 1970 Honda CB160, 2009 Kawasaki 250R

Posts: 107
Broken Camshaft Cover?!

Well, I was breaking into a POS I bought a while back to finally check the valve clearances.

Somehow either I broke one of the bosses that the head cover bolts to the cam cover or I didnt notice that the PO did. I see three solutions each with their own positives and negatives, what say the masses?

1) Do nothing, somehow plug the hole and allow 3 bolts to hold the head cover on. Would be the easiest but oil leakage is possible. I dont like this solution. 1b) JB weld or similar...

2) Replace entire cap with one from another head. I happen to have one, but im concerned since these parts are factory matched I may end up with premature cam journal wear. This may be a temp solution to get me through the race season.

3) Have the current one welded. Im concerned there will be warpage since this is a cast component and I may have the same problem as simply replacing it.

I know the proper solution is to replace the entire head, but with a race scheduled less than 2 weeks away I really dont want to break the engine down with no test scheduled in between.
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Old August 6th, 2017, 11:22 PM   #2
DannoXYZ
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Name: AKA JacRyann
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Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C

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I would use aluminium brazing to fix. Much lower temps so warpage won't be an issue. Yet still quite strong with 40-45kpsi strength. I've used it to fix broken alternator ears, join intercooler pipes, etc.
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