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I picked up a 1999 220 that ran, but poorly. Seemed mostly like the carb needed cleaning. Once i got it home and dug into it, I found the pin that fits into the exhaust valve governor had broken off and made its way through the motor finally lodging in the bottom of the transmission. I came up with good used replacement parts for everything but the cases. I am now the owner of 3 complete cases off of eBay (over $1k). All three of them have damage to the case halve mating surfaces that was not visible by eye on the pictures of the item. The sellers don't offer returns and eBay hasn't been any help.

My question is: Are good cases even available? Seems like these bikes have had their run and if you don't get one with a good case it's just parts and scrap metal. This last case I really thought I had reviewed the photos well but pictures are lousy at showing damage from my current experience.

I have tried mating various halves together but they would all need decking, line boring and oversize crank bearings. Not one of them lines up.

Did you buy sets or single sides?

Can the affected half be repaired with welding, grinding, sanding, etc.?

You are very correct. I have thought for a long time that if the crankcase halves were bad on a bike, it was a huge concern.

Got photos of the damage? I wouldn't hesitate to fill in imperfections in the mating surfaces with JB Weld after serious cleaning and degreasing, but also, ThreeBond 1207B case sealer will seal quite well in minor voids... It sets up in 7-12 minutes though, so you must work fast.

Thanks for the responses. I ended up finding a bottom end in better shape than what I had. I have located a welder with a good history of repairs that is going to take on the other case halves. I will probably slowly build another motor with those parts.