Chain broke and went through the case

Well, I guess I'll probably be moving on from this forum even though I just found it and finally got the Maxim to great running condition 3 months ago... Unless anybody has any suggestions for a hole in the engine case. Here's some carnage shots.

I just thought my chain fell off...no big deal.


Upon further inspection...The blue blob is a chunk of my case.

 

Hard to see in the picture - Did the chain break into the transmission, or just through that cover that keeps it from throwing oil on the alternator?

If it's just through the cover I suggest one of the following options:

1) replace the cover.

2) fill hole with epoxy.

3) have the hole welded up.

4) let the alternator get oily.

Of course if you don't replace the chain and sprockets you'll get a new hole....

 

The hole is directly under the bolt. It is the transmission as far as I can tell not just the outter cover. It is relatively small though so I guess if I want to do the work I might be able to take it apart, have the hole welded and then put it back together. It's just discouraging right now since I just got everything fixed and the bike isn't big enough for me anymore so it's hard to put a lot more time and money into it.

 

Easy guy ... it's not like they didn't think about that sort of thing happening when they made them.

Hard to tell from the Photograph ... but, I don't see anything under the bike that would have me applying for SuperFund Money to get cleaned-up ... so, I'm thinking that the bulletproof vest to keep the fly-away chain from hurting you and the bike did it's job.

Like I said ... all we got to go by is the photographs.
Looks like you might be OK when you get in there and look everything over good.

I hope so.
That's no way to start a Summer.
Maybe its the lighting.
Or the shadows.

I can't really tell.
But, it looks like that rear sprocket needs a Bugle Player that can sound "Taps"

If you come out of this unscathed.
Start the Summer with two new sprockets and a nice O-ring chain!

I got my fingers crossed for you!

 

Don't chuck her aside so easily my friend, you've just started a great relationship. Pull the back end apart and see how extensive the damage is. Post some clear photos for us. A quick stitch with a MIG might be all she needs to be happy again. Count your blessings, a broken chain can be rather catastrophic. I'm glad your in one piece.

 

Get us a picture with the starter removed (it's easy to pull) and we'll be able to tell you a lot more. You might find there's less damage than you think.

 

I'll get some more pictures tonight. A guy I work with came and looked at it today and said he thinks it'll probably be fine. I called the local Yamaha shop and they said they don't have any chains long enough. Anybody have any recommendations on where I should get one and what chain to buy?

 

Sounds like something that happened with my previous bike... a Kawasaki KZ750CSR. Bopping along down the road about 40-50 or so and the chain came flying off. Ripped the front chain guard clean off, which in the process tore a nice hole in a side cover, which let oil come flying out. Plus, the push rod that engaged the clutch was nicely bent. As it was my only transportation at the time, drastic measures were required. What were they, you ask?

JB Weld.

I removed the cover, glued the pieces back together with JB Weld, put a table lamp next to the cover to help the stuff set up quicker, straightened out the push rod as best I could, and went to bed. Got up early the next morning, reassembled the bike, and rode to work. Held nicely until I was able to get to a wrecking yard and find replacement parts.

And this, my friends, is why I refuse to ride a chain-driven bike.

 

O-ring Chains
http://www.oldbikebarn.com/motorcycle_p ... al&Start=0
Sprocket:
http://www.oldbikebarn.com/motorcycle_p ... al&Start=0
Sprocket:
http://www.oldbikebarn.com/motorcycle_p ... al&Start=0

Do the RIGHT THING ... New Chain and Sprockets

 

Thanks a lot for the links. Helps a lot to know exactly what I should get. I was kind of planning on replacing everything even though the sprockets look ok. I figure while I'm doing it I might as well do it all. Better safe than sorry.

I tried to take pictures but I couldn't find the digital camera and my cell phone doesn't have a flash on it. It looks like one of the links binded up and then as it went through the front sprocket it punched the hole in the cover and then bound up on the shift shaft. One of those caused enough tension to snap the next link.

Anyhow, I'll order up the sprockets and chain so that I should get them next week. Is there anything else I should check on/do while I'm in there? There's a lot of chain wax and crap built up in the bottom of the sprocket cover. I'm guessing that's what it is at least. It looks and feels like grease but I don't see why there would be grease there unless it was flung off the chain/sprocket. So I'll clean some of that up.

Anyhow, thanks for the help. Really glad it turned out to be a minor issue on top of being glad it didn't cause an injury. I'll post up and let you guys know what happens. When I get it back together next week. Oh, last thing. I called the local Yamaha shop and they said I need a 104 link chain. The one you posted is 110. Do I just need to cut 6 links out of it or was the shop wrong (wouldn't surprise me)? Thanks.

 

Call the 800 Number at OldBikeBarn.

Get somebody one the line who knows his shit.
Get a O-ring Chain
Steel sprockets.
New Bolts and Nuts to use on the rear axle tension adjuster.
Don't "Thumb-it" ... or, "Eyeball-it" ...
Measure the slack and rotate that rear wheel a few times and measure it again before you lock-it-up!

 

If there's no oil leaking then it's salvagable. Pull the chain cover, clean and inspect. A few chunks missing is no big deal.

So long as it hasn't bent/broken the gear selector shaft then just whack a new chain on and ride away.

I've had a few chains break over the years but never scrapped a bike because of it.

Dig in and remove the gear linkage and three? bolts to get the cover off and check it.

BTW, replace both sprokets if your putting a new chain on. It broke for a good reason.

 

Well little bit of an update. I got the bike apart and filled the hole with JB Weld. It looks good enough for being buried under the starter and generator. My engine isn't very shiny to begin with so the grey patch fits right in.

Anyhow, I got the new sprockets and chain from OldBikeBarn. The sprockets look good except that the drive sprocket appears to be a tooth or two smaller than my old one. Not terribly worried about that though. I'd like the bike to have a little more acceleration as I rarely take it over 40 (city only) let alone over highway speeds.

The chain on the other hand is a whole other story. It was WAY too narrow and doesn't even match the new sprockets. I've emailed OBB and might call tomorrow if I get time during the day. I hate that I've had to cage it everywhere for the last several weeks. I might end up just sending the chain back and going to the local Yamaha shop. At least that way I will be riding again and their prices really aren't that bad (particularly since I now have to pay return postage for the chain to OBB).

Anyhow, sorry for the rant/complaining/whining/long windedness, I just want my bike back. Oh yeah, I also ordered a pair of those aluminum starter/horn buttons off ebay since my starter button broke off and it would be almost as much to use a button from radio shack. Oh well, hopefully it'll be back together before it has to go into storage... :cry:

 

Another update, OBB emailed me today and said the chain is suppose to be a 530. I went back to their site and put XJ550 in and this time it shows no chains (even though it previously gave a bunch of 520 chains which is why I ordered the 520). Anyhow, they said they'd ship me out the 530 and would refund the 520 when they get it back. Hopefully it won't take too long to get the new one.

 

Welp, last post unless people want pictures. OldBikeBarn sent me the correct chain, just got it in and went for a ride. Thanks for all your help.

 

Sounds like a nice save to me!

Post up some pictures of the repair. I am interested!

Jim

 

good to hear everything worked out!

 

Excellent! Let the wind blow man, just let it blow. You aware that you can get new plastic starter buttons from Mikes XS site? I think he's been linked from us several times for all the stuff that crosses over to the XJs.