Damaged crankcase with pictures -- FIXED

I would only tap down to the base of the existing hole, definitely not deeper into the casing. There will be enough thread (probably same as original with longer bolt).
 
Not to siderack this thread but this is what I worry or wonder about the new rockets? Guess if you have a long enough inseam you get a couple trys :)
If i was home I'd take the leftover engine case and drill it just to see how much further you could drill it for new threads.
 
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So what if you break into the inside? Use a shop vacuum to pull all drill shavings and cutting oil while drilling and tapping. Drill stops are available to clamp around the bit to act as depth stops. Just keep setting it deeper 1/16" at a time. The thread lock around the stud threads will stop any oil leaks. The fact that the bosses and ribs broke free of the case proves the wall below the bosses was stronger than the boss. If not, the case would have cracked around the ribs and you would be looking into the sump through a jagged hole.

Yes, if you have the skills to engineer and build a steel sub-frame to mount the side stand, this solution is a good first option.

You won't be able to thread the broken off bosses over studs and get them to seat tight on the cracked surface as the threads won't align and the bosses have to rotate as they approach the case. So drilling the threads out of them will be necessary. Then you can epoxy the case surface, slide the boss over the respective studs and use a nut to hold the parts tight during set-up. This will keep the surfaces as close to original as practical. There is almost no strength to be gained by having threads in them anyway as the epoxy has about 1/10 the strength of the casting, at most.
 
Great point about blowing through the hole, it really doesn't matter, aside from hitting something behind it. I'll have a look through pics tonight I have and see if happened to catch that specific area to determine what's behind it.

Speedy suggestion of running a bottoming tap and clearing out the threads on the broken off pieces is spot on.
 
Why not claim this with your insurance company? It was damaged while you transported it. Stuff happens, but that's why we carry insurance!
And after reading all of these posts, it seems a repair is dicey at best!
I know that my renters insurance covers damage like that, and I don't see why my motorcycle insurance wouldn't either.
 
Why not claim this with your insurance company? It was damaged while you transported it. Stuff happens, but that's why we carry insurance!
And after reading all of these posts, it seems a repair is dicey at best!
I know that my renters insurance covers damage like that, and I don't see why my motorcycle insurance wouldn't either.

Careful with this, the cost of repair will be very high if quoted by a dealer.

We're talking thousands. Looking at the fiche parts alone are like 4,400 + labor to drop, split, reinstall, probably no less than 2k.

If you DO go that route and they total it, I'd suggest buying back and selling salvage here to some enterprising captain after moving all your custom bits to a new R3 :)
 
just thinking
why not modify the kickstand bracket so that it uses the two bosses above the broken bosses and then add material to bring it down to the bottom cover. like two or three bolts for extra strength
 
O.K. I got a bit of time this afternoon, here's a layout of the crank case in this area.
There's a rib directly behind the rearward holes.
The threads are 24 mm deep.
And there is a bulge behind the forward bolt hole.

Crankcase.jpg
 
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