I went to change a weeping base gasket on the front cylinder and this is what the bore looks like.

Notice the cracks...

Advice needed...

Put back together and run it till it dies or replace crankcase?

Other options available?

Please reply.

Thank You

 

I'd replace them, before it scatters itself all over your leg.

 

Yup, there is only one solution here that is safe and works properly...unless you know a really good ally welder.

 

Thank You for the input.

I had no idea the damage it was a big surprise when I opened it up.

 

I would go with some S&S cases.
They are supposed to be stronger than the OEM ones.

 

My advise is ... Dont even think about using this case again.
The torque on the cyl. stud started this crack and if used again
the same torque will cause this crack to migrate further into the
" trashed motor zone " !

 

MoCo ReMan program? Put it back together, send it off with a couple large, get a new motor back.

 

Re welding ...

I've seen miracles done on heads, I'm not so up on cases. That would also require a lot of machining up afterwards, so you'll probably find used stock cases cheaper than doing so. What year is it? Go for the later Evo ones if you can ... 95 up. Though there are plenty of older ones still doing 100,000 miles.


One related question for the Pros ... are H-D or other makers such as S&S and Sputhe etc cases heat treated in any way? If you weld them up, do they then need de-stressed or other treatments afterwards?

Thanks.

 

I heard they stopped the reman program.

 

Damn Bagger, that sucks, I feel you man. More than once I've found unwelcomed surprises when I've opened engines in the past. If you're able to do the work yourself, a new set of S&S or Delkron Cases might be the way to go. If you can't do the work yourself, the cost of a rebuild with new cases can get pretty high. Probably close to the cost of a new Ultima engine. Unfortunately HD stopped their reman exchange a while ago. Another option would be a used running engine. They can typically be bought for around $1500.00. Sorry but that's about all I can come up with for options.

Best of luck getting back on the road soon.