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Yamaha xt600e 2003 dj02 crankcase right broken Yamaha xt600e 2003 dj02 crankcase right broken
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 12 Jun 2020
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Yamaha xt600e 2003 dj02 crankcase right broken
hi I have a Yamaha xt600e 2003 dj02

and my crankcase the right side is broken, I want to know if I can use crankcase from earlier years like 1990 or 1986, because I don't find newer.
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Old 12 Jun 2020
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I must be blind - I can't see where it's broken. I DO see casting marks which might look like cracks. Can you put an arrow where it's broken?
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Old 13 Jun 2020
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in the second picture I draw a black line, there is where is cracked


I am disarming the engine, to see if I can weld it, but I prefer to put a crankcase. if I can use one from a earlier model it would be great, I cant find a 99-03 one. on eBay I just found 84, 88, 90. and some are expensive.
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Old 13 Jun 2020
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look in the yellow circle
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Old 13 Jun 2020
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Quote:
Originally Posted by traians View Post
I am disarming the engine, to see if I can weld it,
It is non repairable, my 600E cracked in the exact same spot, buy this one (nearest to you).

https://www.ebay.com/itm/1990-90-Yam...MAAOSwb4VbqlJS

Mezo.
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Old 13 Jun 2020
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but do you know if I can use crankcase from earlier years, if I can use it I can order it right know
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Old 14 Jun 2020
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Originally Posted by traians View Post
but do you know if I can use crankcase from earlier years, if I can use it I can order it right know
Only the 3AJ.

Mezo.
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Old 14 Jun 2020
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mezo, just out curiosity, whats the difference that makes it impossible to use later model cases?
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Old 15 Jun 2020
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Quote:
Originally Posted by turboguzzi View Post
mezo, just out curiosity, whats the difference that makes it impossible to use later model cases?
Not sure if i understand Bob? later as in the 4PT? i know the clutch actuation is different on them (being on the right) where as the 3AJ & 3TB are the same side.

Geoff knows more on engine swaps than me, he`s done most.

Mezo.
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Old 15 Jun 2020
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Quote:
Originally Posted by Mezo View Post
Only the 3AJ.

Mezo.
The 3AJ is the only one i can use??
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  #11  
Old 15 Jun 2020
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Originally Posted by traians View Post
The 3AJ is the only one i can use??
Your bike has an e-start right, most of the early bikes are kicker only, the 1VJ was both kicker & e-start but uses a unique starter that only fits that bike.

Your bike is a 3TB, it is basically the 3AJ engine carried forward.

Im unsure if the Belgarda or the TT600 cases will match? but whatever it must be an e-strart engine.

Mezo.
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Old 16 Jun 2020
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Quote:
Originally Posted by Mezo View Post
Your bike has an e-start right, most of the early bikes are kicker only, the 1VJ was both kicker & e-start but uses a unique starter that only fits that bike.

Your bike is a 3TB, it is basically the 3AJ engine carried forward.

Im unsure if the Belgarda or the TT600 cases will match? but whatever it must be an e-strart engine.

Mezo.

Mine is the 4pt, the last year of the xt600e.
The 3TB is 1990 and up. So you think i can use the crankcase cover?

Thank you!
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Old 16 Jun 2020
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Quote:
Originally Posted by traians View Post
Mine is the 4pt, the last year of the xt600e.
The 3TB is 1990 and up. So you think i can use the crankcase cover?

Thank you!
Sorry i missed the year, so the main difference is how the clutch is operated, on yours the 4PT it is from the RH side & on previous models its from the LH side, i dont not know if this makes any difference internally though? i will try & find out if the case are the same.

EDIT: I sent Geoff a message so he may chime in soon with your answer.

Mezo.
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Old 16 Jun 2020
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I spoke with Geoff, short answer is NO because of the clutch issue, if you did it with an older case (if it can be done) you would need the whole clutch, the rod end, clutch cable, cover & brackets, and not 100% if it would even work (never done it).

He says your better using an original case (4PT)
Last edited by Mezo; 16 Jun 2020 at 10:54.
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Old 16 Jun 2020
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Originally Posted by Mezo View Post
Sorry i missed the year, so the main difference is how the clutch is operated, on yours the 4PT it is from the RH side & on previous models its from the LH side, i dont not know if this makes any difference internally though? i will try & find out if the case are the same.

EDIT: I sent Geoff a message so he may chime in soon with your answer.

Mezo.
thank you! I appreciated it
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