Off to a BAD Start (With Opinion Poll)

[Nunya_Binnez]

So I finally got around to pulling the plastics off of my newly acquired prize (my '93 FZR600) to figure out where all the oil was leaking from. As it turns out, the PO apparently over-tightened one of the sump bolts (left-front corner) and exploded the threaded boss in the case. It was "repaired" with JB Weld...poorly.

Still wrestling with my options. I know I should bite the bullet and have it welded, but I've been contemplating doing a "good" epoxy repair (if there is such a thing) and then saving up to just replace the motor altogether.

Opinions?

[DonTZ125]

For such a non-bearing area, I'd try the JB Weld again. Build up the area, fill the grooves, then drill and tap. If the threads are in sufficiently good condition, you could simply oil up a bolt, thread it into place, then JB Weld the heck out of the surroundings. Once the JB has set, the oil will allow the bolt to unscrew.

[sweekster]

A good epoxy will work, as Don just explained. My suggestion would be to try the epoxy first, then if that doesn't work THEN look into having the welding done or motor swap.

[Nunya_Binnez]

I appreciate your replies. It should be noted that my riding season is pretty much over, so I am not looking for a fast fix. I will have the motor out while I do some frame work over the winter. I am planning to clean it up and have it powder coated satin black before spring. While it's out would be the time to have it welded if that's what I end up doing. That said, epoxy is NOT out of the question.

BTW...I was mistaken in my OP, the broken boss is on the left REAR corner of the sump area, right by the water pump(?). Really tight to get to as the radiator hose is in the way. The boss was literally split up the middle. The bolt is still in place, but oil is leaking past it pretty good. Call it three drops per hour.