Can this be fixed or do i need a whole new crank?

03. Is this done?

03. Cracked. Is this finished?


Hello everyone, In 2008 I got my twin boys 2 used LT80's. A 2003 red/black and a 1987 blue /yellow.The red (03) was a Cadillac it had the tool kit bag under seat,headlight, orig stickers,oil injector even the clips to hold wires and orig 20 in tires. The 87 was raw, pull start, bling star front bumper, Dg pipe 16in square tires, racing stickers everywhere and it had to be 30 lbs lighter no oil inj. It looked like the big bikes everyone loved the yellow, but the red would smoke it.. lol. I thought it was because of the tire size but the 87 /yellow had a top end bog. Nothing major it still climbed hills n ran just as strong , just not in a drag. The Dg pipe was too loud so we switched to a stock pipe. Same bog and I got biceps pulling that darn cord. It got to where the kids would go ride the red n come back n cheer when I finally got the yellow started. They eventually cracked the case on the red/03.. Got a kx60 and they've sat ever since....
Now we're trying to bring em back. We started with the 87 being the fast1 had a broken case. We changed the rollers , variation, fixed face basically front clutch has been done over( the rollers were shot n gouges all in plate). Even hooked up elec start. It started ran good. Should of left well enough alone!!! BUT I wanted to check stator n sand magneto(Wanted it better than before) My puller for magneto kind of messed up the thread. Bolt won't go back on. Do I need a new crank??? My son's not too confident in splitting cases. Said keeping it straight gonna be hell n he'd rather not. Is the 03 finito???? Here's a cpl pics..... Thanks in advance. Atv mom.

 

When I was an apprentice, one of the persons I worked with had a thing called a bolt saver, it was two hardened steel plates with different sized half holes threaded in, slip it over damaged bolt, stud, whatever onto the good part of the thread, clamp together and wind off like a nut. Works a treat on that type of damage. However I'm sure they are hard to find so, what I use myself, is a metric thread file. These have 8 different pitch threads on them, you chose the correct pitch for your crankshaft, and file the damage away until it matches the rest of the thread.

Jack will know if those cases are salvageable, but I suspect a used motor may be the easiest way out with that. Trouble is, LT80s are suddenly very valuable again and far fewer are being scrapped, which I guess is why your machines are being revived.

 

Merryman, thank you much for the reply. I'm gonna head out this morning and pick up that metric file. (Pretty sure it's a m6). I was looking on YouTube before I posted and saw a product called helicoil , might buy that too . Yes lt80 cases seem to be high , but I usually only see left side. I'm never gonna sell these bikes(toldthe boys/men they're still mine).lol..
My son thats helping has vowed to smoke the red bike .(15 yrs later .bahahaha). They're so competitive but in a cute way. First thing they do is wrestle to the floor as soon as they see each other. EVERYTIME!!! It was his plan toget "Moore power" on the 87 n not his brothers.. (I Knew right then ... it wasn't for his nephews) LOL. Anyways thanks again merryman.

 

Oh wow, just looked again ... helicoil seems to be inserts for female type thread's. File it is.(Will keep ya posted)

 

Oh boy. lol. The cases "may" be able to be welded. It seems to be a clean break (so to speak).
Good news is the crank can be saved. I got these things you put in a drill and it fixes the end.
Big project for sure.

 

Hey Lt80 (jack), thanks for your reply and to merryman I did get the metric thread file but I couldn't get the magneto off. 🤯We did get the bike to start, but since the hiccup I was afraid to start it again without the bolt thinking the stator might spin out of timing. I have a new stator but it was a cheapo and doesn't have a timing mark. Actually I have a bunch of new parts.. ( front clutch seals, both rear clutch bearings and clip, suzuki .50 piston,rings,circlips, stock bore cylinder and head). On the bike now is a amazon top end .(practice ) but I hink we might be over our heads... My son is a trucker and is otr right now. But here's a couple pics.. and I'd love you to work on this motor. Really both but I ordered another and it isn't here yet. Thanks again fellas. Atvmom/Trina.


Old pic. B4 install.

Metric file




2 zuki cylinders


2 zuki heads

 

Hey Lt80 (jack), thanks for your reply and to merryman I did get the metric thread file but I couldn't get the magneto off. 🤯We did get the bike to start, but since the hiccup I was afraid to start it again without the bolt thinking the stator might spin out of timing. I have a new stator but it was a cheapo and doesn't have a timing mark. Actually I have a bunch of new parts.. ( front clutch seals, both rear clutch bearings and clip, suzuki .50 piston,rings,circlips, stock bore cylinder and head). On the bike now is a amazon top end .(practice ) but I hink we might be over our heads... My son is a trucker and is otr right now. But here's a couple pics.. and I'd love you to work on this motor. Really both but I ordered another and it isn't here yet. Thanks again fellas. Atvmom/Trina.


Old pic. B4 install.

Metric file




2 zuki cylinders


2 zuki heads

 

Hello fellas,,, I wrote a comment but didn't seem to post. Anyway thanks for your reply lt80(jack) and merryman ,i did get the metric thread file but I can't get the magneto to budge (I'm gonna get it) lol. My son is otr right now hope I'm not in over my head. We got the 87 running with a cheapo top end (practice) but I have the orig suzuki cylinder, piston.50 over, New rollers, gaskets seals., bearings etc. I'll post the pics.
Jack I'd love to send you the parts and have you work your magic. I think I can maintain them afterward.. (Footpegs already cut). All rollers are in Now, if you have the time and accept to do the work is there anything I can do before hand( remove rollers or cut shoes to 180g?) or send the parts n get out the way. thanks again in advance.(now I wish I would of spent more time in garage with hubbster)


Metric thread file





Rear clutch bearings n clip



Rear axle bearings ...gonna attemp this tonight.

 

Hello again guys... Thanks for your reply Lt80 and to merryman I got the thread file but still cant get the magneto off (im gonna get it).lol. My sons otr(trucker) so no help from him for anther 10 days or so. I think i might be in over my head .I have a bunch of parts though..lol. Suzuki cylinder andsuzuki .50 piston( used amazon for practice)works pretty good though.New rollers, (4 installed), front clutch seals,rear clutch bearings and lil clip, rear axle bearings n seals ,rear brake shoes(gonna try n tackle rear end stuff),new gaskets, pull starter, stator, (battery,cdi/coil.already in) Etc.. ill send pics . Id rather send this motor to you Jack(lt80).. and spend my time working on brake lines.. lol. If you have the time and accept the job , Id need plastic surgery to get the grin off my face.


Rear clutch bearings n clip

Rear axle bearings ...gonna attemp this tonight.

 

Hello again guys... Thanks for your reply Lt80 and to merryman I got the thread file but still cant get the magneto off (im gonna get it).lol. My sons otr(trucker) so no help from him for anther 10 days or so. I think i might be in over my head .I have a bunch of parts though..lol. Suzuki cylinder andsuzuki .50 piston( used amazon for practice)works pretty good though.New rollers, (4 installed), front clutch seals,rear clutch bearings and lil clip, rear axle bearings n seals ,rear brake shoes(gonna try n tackle rear end stuff),new gaskets, pull starter, stator, (battery,cdi/coil.already in) Etc.. ill send pics . Id rather send this motor to you Jack(lt80).. and spend my time working on brake lines.. lol. If you have the time and accept the job , Id need plastic surgery to get the grin off my face.


Rear clutch bearings n clip

Rear axle bearings ...gonna attemp this tonight.