Rear Case? 2000 1500


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johnfliesagain
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Rear Case? 2000 1500

Postby johnfliesagain » Sun Jun 12, 2016 9:16 am



Oh Dear my "free bike" is beginning to go sour.

While removing the Compufire alternator (to replace seal Chicago Rawhide 9878) I heard snap.

From everything that I can read in the Honda manual and on Partzilla it looks as if not only is the alternator broken, but also where it mounts on the bike.

I see the part as being the entire rear case. and according to Partzilla all 37 additional pieces just to replace the one part, let alone pulling the entire engine.
Oh dear.

Patzilla says the rear case is "only" $438.32 ! Part : 21111-MT2-010 CASE, RR. (edit) opps!! No Longer Available,,, but through ebay maybe $39.99 for a 1998 same part number!

Can some one please tell me that is not true? That the alternator mount is a seperate piece and I just can't find it ?

A very sad John in Baltimore. :(


Last edited by johnfliesagain on Sun Jun 12, 2016 10:33 am, edited 1 time in total.
John in Baltimore
A proud owner of a 2000 1500SE
:D Did I mention it was a Free Gift from a co-worker?

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Fatwing Chris
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Re: Rear Case? 2000 1500

Postby Fatwing Chris » Sun Jun 12, 2016 10:33 am

Just went and had a look on HDLParts and that is part of the rear case.Saying all that though I think a good welder could repair that one a lot cheaper.May even be able to do it on the bike,but if not one way or the other it has to come off.
If I'da known it would last this long,I'da taken better care of it.
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johnfliesagain
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Motorcycle: 2000 GL1500SE Anniversary Badge
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Re: Rear Case? 2000 1500

Postby johnfliesagain » Sun Jun 12, 2016 10:51 am

yeah well just editited the post to reflect NO LONGER AVAILABLE and an Ebay price of about $40.00 plus seals and other stuff of course.....
http://www.ebay.com/itm/1998-Goldwing-G ... e8&vxp=mtr
don't know about TIG welding in place might be more than just a crack it centered on the threads for the top alteranator bolt but thanks for the thought and idea.

a sad John in Baltimore
John in Baltimore
A proud owner of a 2000 1500SE
:D Did I mention it was a Free Gift from a co-worker?

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Happytrails
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Re: Rear Case? 2000 1500

Postby Happytrails » Sun Jun 12, 2016 1:39 pm

Sorry to hear about your problem. But you may be in luck after all. You have an enormous used motorcycle parts warehouse in baltimore. More than likely you can find it there. 8-)
1991 GL1500 SE Anniversary Edition
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johnfliesagain
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Yamaha 79 XS750; 80 XS850
Picture of one of my Triples Yamaha xs750 '79 at Timonium Bike Show 2015

Re: Rear Case? 2000 1500

Postby johnfliesagain » Sun Jun 12, 2016 4:26 pm

yeah, Dean at Baltimore Cycle Salvge is a nice guy. When I needed the progressive springs on the front I went to him for the labor!
I have him in my contact list(speed dial they used to call it!).

But the one in Georgia looks good. Maybe I should talk to Dean about labor!

Or is it easy to pull a motor ? I have the Honda shop manual all 700 some pages of it!
John in Baltimore
A proud owner of a 2000 1500SE
:D Did I mention it was a Free Gift from a co-worker?

ozburner
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Re: Rear Case? 2000 1500

Postby ozburner » Tue Jun 14, 2016 2:10 pm

If I were closer I would weld it for you. Find a welder who does marine engine repairs (outboards). They have the skills to heliarc that with the bolt in place as not to kill the threads.

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johnfliesagain
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Yamaha 79 XS750; 80 XS850
Picture of one of my Triples Yamaha xs750 '79 at Timonium Bike Show 2015

Re: Rear Case? 2000 1500

Postby johnfliesagain » Fri Jun 17, 2016 10:33 pm

ozburner wrote:If I were closer I would weld it for you. Find a welder who does marine engine repairs (outboards). They have the skills to heliarc that with the bolt in place as not to kill the threads.



You know I have been looking at a lot of Ebay photos of the case. I think that the cracked part of the case is actually on a, uh , extension of the case removed from the part that seals the alternator housing. you know sorta like a cantelever bridge support what should I call it?

Tomorrow I will pull the alternator and actually confirm is the area that houses the alternator is clear of cracks. Ozburner you maybe on to something here, course I now will have to find a welder, but there are a lot of cycle shops here that surely one could recommend a welder. And find out if they can work in that space. would require removal of the fuel tank and hoses I guess. Tight space, yes?

This past week I have been too busy trying to repair my fuel line on my 89 SAAB turbo convertible to look at the bike. And that was fun. Fuel line runs inside the car under the left sill . A hard plastic tube.... they dry and crack.16 feet long! Thank the Lord that the pinhole was outside ( dripping on the engine of course) rather than inside the car!
John in Baltimore
A proud owner of a 2000 1500SE
:D Did I mention it was a Free Gift from a co-worker?

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johnfliesagain
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Motorcycle: 2000 GL1500SE Anniversary Badge
Yamaha 79 XS750; 80 XS850
Picture of one of my Triples Yamaha xs750 '79 at Timonium Bike Show 2015

Re: Rear Case? 2000 1500

Postby johnfliesagain » Sat Jun 18, 2016 8:54 pm



So I got the alternator out. The top mounting screw bracket on the rear case hastwo fractures : one seen in the photo at, say, 10 O'clock and the other hidden on the backside at, say,
2 O'clock. ain't no way it can be welded in place.

I had thought of using a smaller diameter bolt that was longer and attaching a nut at the end, but I would not trust the pie shapped piece to not fracture further.

The suggestion of welding in place is not good as the backside fracture cannot be reached in place.

Damn I was just beginning to have confidence on working on this bike, and more over, as a heavier bike , getting the feel of ridding it.

My local multi-dealership service department said maybe 25~30 hours to remove replace the engine and attach a used rear case cover.... at $110.00 per hour. or $3,300.00 labor

I don't think so. For me take 30 hours and double it. Well maybe not quite... but I don't have one or two special tools...

I gotta sleep on this one.
John in Baltimore
A proud owner of a 2000 1500SE
:D Did I mention it was a Free Gift from a co-worker?

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Bluewaterhooker0
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Re: Rear Case? 2000 1500

Postby Bluewaterhooker0 » Sat Jun 18, 2016 11:13 pm

OK. I have a half-assed suggestion, only because I'm totally void of whole-assed suggestions.

Have you removed the alternator to determine if the cracked wedge on top can be pulled back into position ?
I so, are you also considering replacing the alternator with one that has the complete mounting bracket ?
My idea is to clean the fractured surfaces with a spray cleaner, maybe electrical contact cleaner that has no lubricating residue. Cleaner only, to leave a clean, greaseless surface. Use JB Weld, which is some pretty tough stuff (epoxy with an aggregate), pasted into the fractures, and then pull, C-clamp, hose clamp; whatever will pull the fractured tab back into position until it cures. Run a tap through the threads to clear out any epoxy that might have made it to the internal threads. Attach the new alternator which will effectively provide an extension of the piece just repaired. Then attach a hose clamp around the repaired section, as well as the new alternator flange, tightened as tight as possible. Then insert and tighten the mounting bolt. The JB should do a pretty good job of sealing the fracture and providing some structural strength, and the hose clamp should reinforce it, providing most of the structural strength. I would probably not tighten the bolt to specs, but I would think the other 2 bolts would do a pretty good job of keeping the alternator in its place.

That's all I got. I warned you it was not a whole idea. But, short of $3000, it is an idea.

Another thought would be to use a small ring shaped section of pipe, that, if your are lucky, would just fit over the flange of the repaired case, to add the structural stability in place of a hose clamp. It could even be JB Welded in place, if sizing permitted. Then you could file the whole repaired flange smooth to facilitate mounting the alternator. From the looks of it, I'm guessing that broken alternator tab is what compromised the case mount in the first place. Creating a vertical pull on the bolt, and the consequential cracked case mount.

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seelyark1
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Re: Rear Case? 2000 1500

Postby seelyark1 » Sun Jun 19, 2016 12:28 pm

I'm pretty sure that you can find a whole used engine for much less than that price. And if you have to r+r the engine it would be way easier. Check around at some of the Cycle salvage places. ;)


Ride safe, and smart. Asphalt is like #1 grit sandpaper. Dave


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