2005 Yamaha Zuma Crankcase crack intake screw
 

Ok so I ordered a new case, this probably causing major air leak. My instinct is this might not be reasonably repairable. Metal experts, welders? Help!

What exactly is wrong? I looked at the picture but it makes little sense. I don't have a horizontal engine for reference here.

The screw part where you attached the reeds/intake onto the crankcase has a screw hole that the metal has cracked. I can take more pics if that helps.

Your'e aware that those 4 screws that hold the reed cage are only 10Nm in torque, and that cage has to be sealed well or you will have lean issues. You may be able to find a GOOD aluminum welder and have them fix that broken tab, since trying to run it with only 3 screws will not work well. How did that happen anyways?

Yup, air leaks no good with 2 stroke, and yes I’m aware the reed cage and intake boot go there. It happened by torquing down too tight.

well if its new id tell them it came broken and send it back if money is tight and you like doing work you can dril 4 small holes in the center of the case while both piece are together drill 4 holes becareful not to drill thru top or bottom of case and you can use a small tap and dye set https://www.harborfreight.com/carbon...xoC1_gQAvD_BwE after you made the 4 new holes use a good gasket With a gasket sealer and locktite your 4 new little screws in place of the larger one then once you are all done with that just for good measure you can put that bo;t in the broken hole as best you can rough up above the thread area best you can put bolt in after youve done all the above and tighteng the other 3 main bolts and ur 4 new tap and dye bolts you can put some jb weld on top of that old bolt well its in the hole and you will more than good if done as stated