Motorcycle Repair: cracked case, oil leaks, cracked case


Question
Hey Mike,  I have a 1969 XLCH sportster, that I just bought.  Bike only has 500 miles on this rebuild,  motor was built by Thunder rod cycles in Texas.  Had a few oil leaks behind oil tank, so I took tank off and noticed that the rear motor mount was broke.  I got my book and went to work.  I pulled primary case cover, clutch, and kick start gears, pulled kick start shaft and replaced motor mount.  When I was inside the motor, I noticed that there had been three cracks around the kick start bushing in the case that had been welded up, looked like they had done a good job.  I reassembled bike started the bike and went for a test drive.  About 5 miles into my ride I heard a pop, and then gears grinding.  We hauled bike home took primary cover off, and found that the three cracks had re cracked around the kick start shaft.  I think the swing arm bearing and nut assembly hit the case and broke it.  What do I do now.  Can I have it welded again, do I have to replace the left hand case, do I have to replace both left and right case.  If so, how much of the motor has to be torn down, what will have to be replaced on this new of a rebuild, and who can do these things.  I am kind of frustrated, just want to know what to do next.  Any advice would really help.

Answer
Without seeing it its hard to tell you if it can be fixed, but I do weld alot of cases and trans cases without any problems. The biggest thing in welding alum. is you have to know what your doing.
First, the cases would have to be split and the internal parts removed, so your looking at a complete rebuild of the motor. There again, without seeing the internal parts, it would be hard to say what would need replacing.
Good luck and happy riding
Mike