Broke off chuck of the case

[Napawineguy]

I have a 05 1200 custom, want to see if anyone else has had this problem, because im trying to figure out a good way to solve it. So what happened is a chunk of the case broke off, its the top half of the area that the starter bolts to. Right through the center of the bolt holes. So i took it down and got it tig welded, but because its through the center of those bolt holes, when i bolted the starter back on it started to sepperate it again there. Looking for anyone who might have had the same problem and how they fixed it, if they fixed it. I would hate to think my motor is trashed now because of this.

[rocketnorton]

bad weld job
holes shoulda been opened up to resemble trough, then filled in solid, redrilled n tapped
ideally welding would be on both sides, sometimes not possible tho

[Tomcatt]

Originally Posted by Napawineguy

...a chunk of the case broke off, its the top half of the area that the starter bolts to. Right through the center of the bolt holes. So i took it down and got it tig welded, but because its through the center of those bolt holes, when i bolted the starter back on it started to sepperate it again there...

If you want (good) advice we need a couple pics to see what you're dealing with.

[Napawineguy]

I will take some pics of it. I dont think it was a bad weld job, this is a good shop been around a long time here, think he just did the best he could with what he was working with. Like i said ill go out now and take some pics, its just a bad spot for a brake, and hard to get into that area to weld. I just lookes and it looks like its not to hard of a job to install a kickstarter kit. Avout the only thing i havent done yet is pull my trani out and do any work on it, but i girss a good time to learn. Not sure what the cost of the kit is though.

[John Harper]

How did it break?

John

[Napawineguy]

Ive been trying to attatch pics, but for some reason this site has made that no easy task. Im not a 100% on how it happened. Just one day noticed a crack on the top part, so put so jb weld on, and had no problem for a long time, but changing out starters finished the break, and if i had to guess it would be that thats what started it. Im thinking im gonna have to save up and put a kick start kit on, but seeing how i just took a huge hit on my income, thats going to be a little bit. Im sure i can do the work myself, and then i can just have that piece tig welded and the holes sealed, and with no starter there, shouldnt have a problem again. I just dont see how to get any strength back in that areawith welding again. Anyone with a sportster thats yhe same year, or years with the same set up, just picture where your starter attatchesand through the 2 bolt holes right through the center, the top half of that area the starter attaches to is broke off. Thats the best i can describ it since i cant get the pics on, but ill keep trying.

[Napawineguy]

https://ibb.co/GpTJrLg

[Napawineguy]

Sorry buy its forcing me to do these 1 at a time https://ibb.co/b1B4NG1

[rokytnji]

So I can see it

[rokytnji]

Not sure why it is separating. No bolt holes close by or locating pins.

Maybe have to stud the holes on both sides and over gasket it?