Hi
After the drive chain snapped I have a hole in my crankcase and crankcase cover on my TTR 600.I want to try and get the main crankcase welded and replace the cover.
I have tacken the engine out and was going to get a garage to strip my engine get it welded and reasamble now I am thinking maybe I could strip the engine my self.
Is this a difficult job and what special tools are required?
Will I have to replace all seals in the engine or can they be reused?
Has anyone had an crankcase welded after chain breaking ?
Are there any things like liquid metal for alluminium that i could try the hole might be a bit big for this but if I replace the outer casing the hole will be about 4cm.
Any suggestions thanks John
Does any one have a TTR 600 KIckstart engine mine is 97 or know which XT casings are the same.

[This message has been edited by bolla (edited 01 January 2005).]

hi bolla,

before you start to dismount the engine you should try to find a workshop able to do the welding.
this welding is a tricky job because the material is very thin and is an aluminium / magnesuim alloy.
i wouldn't recommend liquid metal etc. for emergency repair its o.k. but on long term vibrations might be critical. heat-resistant silicon is much better.
it might be better / easier to buy a 2nd hand housing. any xt600/tt60 kick-start housing will fit.
you have to replace the gaskets. if you want to do a good job you should replace the sealings as well. gasket / sealing kits are not this much expensive. ask www.kedo.com .
buy the clymer manual:
http://www.amazon.com/exec/obidos/tg...glance&s=books
best repair book available! will cover also most of your engine.

good luck
klaus
xt600.de / technical dep.

Hi Klaus
Thanks for reply I took my engine to a welder ,he did not think the case could be welded as it is very thin,badly damaged and
the case will distort.
So I am trying to get an engine casings.I am trying to find out about the difference between electric start and kickstart casings is it possible that an older xt with electric start only will still have the hole in the right hand case (main crankcase) for the kickstart shaft I think they changed the same time the clutch cable was moved also do you think my gears etc will fit no problem.
Thanks John

John
Although I cannot speak about the XT, I had exactly this problem with my FJ1200 several years at about 75,000 miles. The fracture was confined to the part of the crankcase that houses the clutch, as a result of the chain bunching up on the front sprocket when it snapped at high speed (preferable to locking up the rear wheel!).

I stripped the engine down completely after my local bike shop told me about a competent alloy welder nearby. After stripping, I rebolted up the empty crankcase halves, being careful to tighten them up to the correct torque value. The cracks were then welded and I rebuilt the engine. At that mileage it would have been a false economy to put back any of the original bearings, seals, O-rings, gaskets etc so I replaced all of those, honed the bore, balanced the pistons, ground the valves, etc etc. A further 85,000 miles further on all is still well.

It's a good idea to use the workshop manual, even for stripping, as some steps have to be taken in a specific order. I didn't have any special tools but when there was something I couldn't do (like pulling gears or undoing the front sprocket) I took the engine along to my friendly bike shop to help.

I'm now rather particular about lubing and checking the chain ...
Regards,
Neil.