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Old 01-05-2013, 08:20 PM   #16
XTique Rider
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Joined: Dec 2006
Location: Arkansas USA
Oddometer: 7,927
Originally Posted by Joevano View Post
Thanks for the optimism guys, I need all I can get right now. I have started the bike since then and it did dribble.

I've been told (by a professional mech) that you cannot replace half a case. The cases are drilled for the crank as one case and then cut in half. If you replace half, things will not line up and it will leak. That's why they are sold as a set.
I was told the same thing about ,y Rotax Powered ATK, 260...
They sell them in pairs.
I chanced it and used 1/2 a case on it and never looked back. It never game me a minutes problem after that.
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Old 01-06-2013, 12:01 AM   #17
Beastly Adventurer
Joined: Mar 2009
Location: Denmark
Oddometer: 1,076
Seems like a roadside repair to me, shouldn't cause you much grief. You were lucky.
2003 xt600e 155.000km
1986 xt350 100.000km (now sold)
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Old 01-06-2013, 06:41 AM   #18
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Joined: Jan 2011
Location: Richmond, Ohio
Oddometer: 4,155
Originally Posted by Joevano View Post
Let me clarify something. The leak dod NOT come from the crack. The crack is only in the rib.

The leak came from the slight misalignment between the bent crankcase and the cover.

Even better. Prep the crack, JB weld. I'd use some gasket maker on the cover and see what happens. Sometimes that stuff will work wonders.
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Old 01-06-2013, 11:57 AM   #19
Green Chile Eater
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Joined: Apr 2009
Location: Out in the NM Dez somewhere
Oddometer: 6,421
If you replace the case, get both, they are lined bored as a pair (essently matched) when new even though you can purchase a half from suzuki.
"Life's journey is not to arrive at the grave safely in a well preserved body, but to rather skid in sideways, totally worn out, shouting ... Holy Shit, what a ride!"
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Old 01-06-2013, 03:38 PM   #20
Joined: Nov 2009
Oddometer: 20
I was reading your report on the trip last year and was wondering if you fell off the earth after you got home. I also ride a dr650 but let me preface this by admitting I rode a KLR. So hell no that engine isnt ruined. I"d try and BUMP the case back in line, If it doesnt move back in place, I"d clearance the inside so that the gear clears and jb weld it. New gasket and gasket sealer and ride that sucker back to Alaska next year.
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