KTM kicker-gear stripping

[OhioTed]

Friends,

My good buddy John Edwards has a '99 KTM SX380.  Very nice bike, but he's got a problem, which as I understand involves the bolt which holds the kickstarter gear in place.  Bolt keeps backing out.  Please see John's lastest account, following.  Any thoughts on how he may correct, short of changing out the case?  Any information would be greatly appreciated.

Bummed again about the katoom.  I got it all put back together Saturday; let my gasket material set up for 24 hours before I filled it with oil, and then tried to start it yesterday afternoon out in the driveway.  Stripped out the center gear AGAIN.  Completely strips through the entire kickstart motion, and never catches anything now.

Inspection of the bolt hole shows a fine crack in the motor casing.  Somebody (factory? Or original owner???) obviously has tried to fix it with some sort of epoxy looking material.  My guess is the bolt vibrates a bit because of this crack, and thus has the tendency to back out.  I used a few drops of red loctite on that bolt (even though I know you are not supposed to) and it appears it did not hold either.  There must be tremendous torquing pressure on this center gear is all I can think why it continues to fail at this one spot.

So, I'm back to square one.  Question on this 14 year old bike.  I know I can't sell it for **** if not running, so think I've got to tear into it again.  No way will I give it to a shop to try and fix.  Bill would run $400-500 in my estimation for them to do anything to it.

Here's the question.  Do you think I can go in with JB Weld and a small pick like tool and a popsicle stick to help smooth it in to the crack, and try to "repair" it?  I think it's worth a shot.  Second question, after that, do you think I can JB weld that bolt into the hole?  I know you're screwed later if you have to get at that bolt, but I'm desperate here.   What cha think?

Leaning more and more to trying to part ways with that old bike, but I don't want to sell it a huge discount for not running, and I like to try and make things right.  thanks for the input.

John Edwards

[Kip Kern]

Have seen a lot of these in KTM engines. Have to split the cases, weld the area inside aroung the stop bolt and reassemble.

[OhioTed]

Thanks so much for the info, Kipper.  Dumb question - what material is the case constructed of?  Aluminum?  Magnesium?  Kryptonium?  Need to assure welder is located who can do the job.

[OhioTed]

Kip, could you telephone me on this?  I would like to ask you some questions about the job, if possible.  PM me if you don't have my telephone number.  Thanks.  

Ted