Cracked Engine Case Video - Kawasaki KLR 650 Forum
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post #1 of 4 Old 07-11-2012, 08:38 PM Thread Starter
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Cracked Engine Case Video

Hello all. A week or so back I posted on an event that resulted in a cracked engine case at the oil drain plug. The engine is now out of the bike and ready for repair but I now have doubts. Take a look at the video and let me know what you think. I figure my choices are have this guy tig weld it (However I am worried that will build to much heat and get the seam leaking at the case joint), Do some fine Drimmel work in the crack and JB Weld it or just take it down and replacing the case. However at that point I could then go the Tig route. What do you all think?

http://youtu.be/zAmRMQ3M2ng
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post #2 of 4 Old 07-11-2012, 08:47 PM
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Your bike, but . . . I still wonder why you pulled the engine.

Looks like a number of repair techniques could have been tried with the engine in place.

A club member cracked his crankcase, behind the stock bash plate, on a rock while riding the Shenandoah 500.

Had it welded up, no problem.

With the access the free engine provides, I don't see why a competent weld won't fix it. Having gone this far, I'd certainly look for a welder, rather than a tube of J-B Weld.

Still, your call entirely.

Good luck!

--------------------

Oh, yeah; you mentioned replacing the case. Boy-oh-boy, that would be my absolute LAST resort, after EVERYTHING else had failed. YMMV!

Last edited by LoneRider; 07-11-2012 at 08:49 PM.
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post #3 of 4 Old 07-11-2012, 08:58 PM
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Originally Posted by moriver View Post
Hello all. A week or so back I posted on an event that resulted in a cracked engine case at the oil drain plug. The engine is now out of the bike and ready for repair but I now have doubts. Take a look at the video and let me know what you think. I figure my choices are have this guy tig weld it (However I am worried that will build to much heat and get the seam leaking at the case joint), Do some fine Drimmel work in the crack and JB Weld it or just take it down and replacing the case. However at that point I could then go the Tig route. What do you all think?

http://youtu.be/zAmRMQ3M2ng

I think you would be OK to weld. Looks like it's not all the close to the case split right? Shouldn't require a lot of time to TIG up that crack.

How was getting the motor out? Heavy?

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #4 of 4 Old 07-11-2012, 09:48 PM Thread Starter
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Lonerider- You have a good point but with the heat lately I have not been riding much. Pulling it also makes the job much easier on the guy running the Tig. That is the guy I want happy as if it gets messed up the thought of pulling it down to replace that center section will make me cross for some time.

Spec- The weld will be about 1 inch from the case seam. Pulling it was about a three hour job and the weight was not that bad. That coming from a mechanic that used to work on road trucks however....
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