Update: Can these YZ250 Cases be Saved?

GarrettL
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GarrettL
Edited Date/Time 12/19/2017 4:40am
03 yz250 cases. Can these be fixed or no? Bought this bike used and have been pretty disappointed thus far. How anyone could sell this with a clear conscience is beyond me.
Should I just buy new/used ones and scrap these? Anyone have cases for sale??

These first 3 pics are the ignition side. Here's what I found after I scraped off the massive glob of JB Weld.
Also there seems to be a small crack that can be felt by scraping a dental pick across. After removing the
crank bearing, the crack doesn't seem to extend into the bearing surface.





Clutch side...




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RockyRider
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RockyRider 9/26/2017 9:02am
9/26/2017 9:02am
If you knew a good welder you could probably fix the crankcase cracks, but I dont think theres any saving the hole by the clutch actuator. Well..you probably could but it wouldn't be sano..
colintrax
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colintrax 9/26/2017 9:10am
9/26/2017 9:10am
I'd buy new cases, not worth trying to fix.
Plus side to new cases, you don't have to clean them or worry if they were repaired properly.
Markopolo400
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Markopolo400 9/26/2017 9:18am
9/26/2017 9:18am
One time I JB welded a penny over a hole that looked identical to the one on your clutch actuation arm on my 04 YZ250, I was in a real pinch, but I don't recommend it.

If there is any hope of fixing them, call http://trickeng.com/
Paw Paw
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Paw Paw 9/26/2017 9:56am
9/26/2017 9:56am
"How anyone could sell this with a clear conscience is beyond me. "

Used dirt bike sales and the above just don't seem to work together.

Paw Paw

The Shop

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GarrettL
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GarrettL 9/26/2017 10:13am
9/26/2017 10:13am
Paw Paw wrote:
[u][i]"How anyone could sell this with a clear conscience is beyond me. " [/i] Used dirt bike sales and the above just don't seem to work...
"How anyone could sell this with a clear conscience is beyond me. "

Used dirt bike sales and the above just don't seem to work together.

Paw Paw
Yeah I'm inclined to agree with you. Really grinds my gears....
KID858
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KID858 9/26/2017 6:04pm
9/26/2017 6:04pm
Markopolo400 wrote:
One time I JB welded a penny over a hole that looked identical to the one on your clutch actuation arm on my 04 YZ250, I...
One time I JB welded a penny over a hole that looked identical to the one on your clutch actuation arm on my 04 YZ250, I was in a real pinch, but I don't recommend it.

If there is any hope of fixing them, call http://trickeng.com/
Trick Eng x2
harescrambled
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harescrambled 9/26/2017 6:19pm
9/26/2017 6:19pm
Buy new cases...by the time you get that case welded and remachined you'd be able to buy a new (or at least decent used) set of cases
Bruce372
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Bruce372 9/26/2017 6:51pm
9/26/2017 6:51pm
I had a rock in the actuator and got it welded ok, but the center crack is too much...
BobPA
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BobPA 9/26/2017 7:35pm
9/26/2017 7:35pm
Bruce372 wrote:
I had a rock in the actuator and got it welded ok, but the center crack is too much...
Agreed
GarrettL
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GarrettL 12/18/2017 3:19pm
12/18/2017 3:19pm
Update: Decided to try and save these cases instead of buy new ones. Couldn't really find any used ones that looked good either.

Had a local guy weld up the cracks and the giant hole near the sprocket.

While I had the cases apart I decided to get them hard anodized as well. Had a few other parts anodized as well.











Clutch cover got Cerakoted as well.





Acidreamer
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Acidreamer 12/19/2017 4:40am
12/19/2017 4:40am
I hope they hold up for you. Nice looking motor

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