08 engine case replacement part? - Kawasaki KLR 650 Forum
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post #1 of 7 Old 08-31-2014, 11:54 PM Thread Starter
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08 engine case replacement part?

So after 2 years of the drips I am going to replace my engine case due to some damage from a rock not having the short drain plug. Lesson learned! I am to tight to give factory price for one so I am going the ebay route. Does anyone know a year range or design change in those cases that I need to consider or are they all the same? Any help would be much appreciated crew, much thanks and have a good one.
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post #2 of 7 Old 09-01-2014, 08:06 AM
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Drastic move; have you looked into alternatives?

Having case welded?

My all-time favorite is, oversize drain plugs, but . . . sounds like you may be beyond that expedient. Assume you have a cracked case; I'd hope it can be welded, drain hole re-bored and re-tapped, if necessary.
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post #3 of 7 Old 09-03-2014, 07:04 AM Thread Starter
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Wow, 75 have looked at this but know one knows on case specs? I never thought I would see the day I could stump .com
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post #4 of 7 Old 09-03-2014, 07:08 AM Thread Starter
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Yes I am past the bigger hole and weld it up stages. Its time for a proper repair on this one, the patch job is just not working out for me.
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post #5 of 7 Old 09-03-2014, 08:11 AM
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One thing to consider is the title and registration issues that may occur when your frame and engine numbers don't match.

That said, it may be easier to find a complete motor/bike that has been scrapped because of the camshafts running out of oil. The bottom end of a motor with seized camshafts could be just what you need and easier to swap than a bare case.
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post #6 of 7 Old 09-03-2014, 09:41 AM
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moriver-

I have started to answer twice but have stopped because I didn't feel I was really answering the question.

Here goes.

There have been five case designs.

'87-'88
'89-'96
'97-'07
'08-'10
'11+

For replacement on your '08 I would say that anything prior to '97 probably shouldn't be considered. I would bet that such cases would work, but there were a lot of changes during the '96 model year. That included changes to the cylinder, so there might have been some changes to the case as well. I would think that all cases would work, but the post '97 might be better. I might also be full of crap, as the case might be identical. I just don't know for sure.

The problem is, we know that the '88 case was strengthened by the addition of some bolts and bosses, but we don't know what changes were made to later cases.

My suspicion is that they were not significant dimensional changes. They were changes in manufacturing methods, changes in casting tooling, and so on. As crazy as it may seem, the color may be a factor and why the '11+ cases are considered to be a different part number.

If I were you, I would be comfortable using any case back to '97, though I would first try to find '08-'10 cases.

Sorry not to be of more definitive help.

edit: beware the bastiches on e-Bay who split the cases into two sales. They either don't know that the cases are a matched set or they think they can make more money by splitting them into two sales. In either case I say "**** 'em".

Tom

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Last edited by Tom Schmitz; 09-03-2014 at 10:01 AM.
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post #7 of 7 Old 09-04-2014, 01:28 PM Thread Starter
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Much thanks all

Tom that's a great answer! As a frequent lurker here I really appreciate your help. Hats off to you.
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