Hello motorcycle comrades! I have developed quite a problem with my 2003 Savage and figured this would be my best bet to obtain the most honest and accurate answers. To make a long story, short, I am trying to put it back together without really knowing what was done while it was out of my possession... I can fill in the details later, if we can get past this first problem.

I was installing the side stand when I noticed a crack on top of the engine block. It starts between the top 2 bolts on the left hand side crank case cover, and runs to the top left corner of where the solenoid sits (hopefully you can see the photo).

My main concern is whether or not it is worth continuing the build...
Should I take the cover back off and see what happened underneath?
Can it be filled with gasket maker?
Is it even fixable?
What is my next step / where do I go from here?

I appreciate any and all feedback. Thank you in advance!

Yes, I agree with Hiko and you need to take the cover off and see what is underneath.  It could be the washers for the starter idler/torque limiting gear were put in the wrong place.

If that is the only thing broken, you could use JB Weld and epoxy the crack on the inside of the engine.....and try to get some inside the crack.  With a little paint it may not be real noticeable.  JB Weld will hold up better than gasket maker - it works very well on engine blocks.

  Being a 95 this may be damage caused by the motor 's kickback , though not what we're use to seeing ,normally damage to the gears or side case. but a agree you'll need to disassemble the side case, starter gears and motor to be able to see the complete extent of the damage.

Now I know where to start. Thank you kindly. I will update as I proceed.

batman wrote on 05/09/20 at 07:25:44:


How often does that happen?  Is it as big an issue as the cam chain tensioner check?

OOPS sorry I missed that it was a 2003

Might not have gotten a shaft in the recess in the cover, something held it out,, and the bolts being tightened bowed it till it cracked.
Thats why
All Bolts go up finger tight before any get tightened. And gaps are checked, to see its coming up evenly and flat.
Once All bolts are up finger tight, say, nut driver, yes, you can borrow Stanleys nut driver handle,, and dont make a fist grip, get every bolt in, spin them up.. Before ya even spin them up, press the part into position and make sure it is going. Then a quick snug on opposite sides and its gonna stay there. If youre using bigger than 1/4" drive stuff, youre beggin for trouble. A 1/4" drive ratchet with a thumb on the head and opened fingers, using the closing of the fingers to bring the bolts tight, is enough.

Long distance forensic analysis  Awesome!