I have to tend to think that a good aluminum welder could fix it for ya though...& ya wouldn`t even have to take the motor out to do it.
As far as the timing & everything goes...the service manual shows & explains pretty much everything a person needs to know. It all basically just depends on your personal mechanical experience & ability & what you`re comfortable w/ doing. Quad & bike motors really aren`t that complex & mysterious! IF a person can tear down & rebuild a small block Chevy...then they can very easily tear down & rebuild one of these quad/bike motors!
Out of the modern day 4 strokes the Honda motor is probably the easiest & least complicated one to work on IMO.
If you`ve never torn into your motor even as far as to re-shim your cams (which I`m guessing that you haven`t ever attempted since you`re concerned about the timing) then I wouldn`t recommend that you even attempt to be replacing a side case or splitting the main inner cases as it would appear to me that you just don`t have the mechanical experience/ability at this point to pull it off successfully.
`08 KFX450 (White/Black)
~Phoenix Full Exh.
~FCI w/o box
~Procom Prog. ECU
~HC`s Stage 3
~ProFactory Hoses (White)
~Pro Armor Kill Switch Kit w/ Gunnar Killer
~LSR PB BO
~G-Force Wheels w/ Maxxis Razr TT`s (Orange Label`s w/ extra grooving)
~CRJ Lowering Kit F/R
~G-Force Adj. Axle
~KOQ Chain Guide&Case Saver
~Wheel Spacers (Frnt.)
~Race Cut Fenders