Update: Can these YZ250 Cases be Saved?

22897 GarrettL https://p.vitalmx.com/photos/users/22897/avatar/c50_96770540_1286562567.jpg?1294200986 https://www.vitalmx.com/community/GarrettL,22897/all 10/08/10 4 5 78 4

Posts: 83

Joined: 10/8/2010

Location: Edmond, OK USA

9/26/2017 8:58 AM

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

51382 RockyRider https://p.vitalmx.com/photos/users/51382/avatar/c50_Screen_Shot_2016_03_10_at_6.38.42_PM_1457669022.jpg?1457668045 https://www.vitalmx.com/community/RockyRider,51382/all 03/10/16 3 25 210 1

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Joined: 3/10/2016

Location: Nor Cal, CA USA

9/26/2017 9:02 AM

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..

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colintrax

48607 colintrax https://p.vitalmx.com/photos/users/48607/avatar/c50_MXoN_maggiora_NL697_saturday_1474847906.jpg?1474847167 https://www.vitalmx.com/community/colintrax,48607/all 08/25/15 55 3719 36

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Location: Taylorsville, GA USA

9/26/2017 9:10 AM

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.

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Markopolo400

34844 Markopolo400 https://p.vitalmx.com/photos/users/34844/avatar/c50_avatar9000_1_1436970212.jpg?1436969226 https://www.vitalmx.com/community/Markopolo400,34844/all 07/24/12 1 19 1142 35

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Location: NW, WI USA

9/26/2017 9:18 AM

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/

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Paw Paw

31735 Paw Paw /images/default/avatar/c50.png https://www.vitalmx.com/community/Paw-Paw,31735/all 12/24/11 1 605

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Joined: 12/24/2011

Location: Benton, LA USA

9/26/2017 9:56 AM

"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

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GarrettL

22897 GarrettL https://p.vitalmx.com/photos/users/22897/avatar/c50_96770540_1286562567.jpg?1294200986 https://www.vitalmx.com/community/GarrettL,22897/all 10/08/10 4 5 78 4

Posts: 83

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Location: Edmond, OK USA

9/26/2017 10:13 AM

Paw Paw wrote: "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....

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KID858

47040 KID858 https://p.vitalmx.com/photos/users/47040/avatar/c50_image_1443044727.jpg?1443044198 https://www.vitalmx.com/community/KID858,47040/all 04/22/15 3 2 55 1

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Location: Conroe, TX USA

9/26/2017 6:04 PM

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 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

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harescrambled

4569 harescrambled https://p.vitalmx.com/photos/users/4569/avatar/c50_HIG_8945_1588531087.jpg?1588530558 https://www.vitalmx.com/community/harescrambled,4569/all 04/01/08 3 1 https://www.vitalmx.com/community/harescrambled,4569/setup 50 1510 36

Posts: 1560

Joined: 4/1/2008

Location: Warren, OH USA

9/26/2017 6:19 PM

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

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Many thanks to everyone helping me out this GNCC season: SRT Offroad, Acerbis, FCR Suspension, O'Neal Racing, Evans Waterless Coolants, Rekluse, Twin Air, Braking Brakes, Carbsport

Profile image credit Ken Hill Photography

Bruce372

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Location: USA

9/26/2017 6:51 PM

I had a rock in the actuator and got it welded ok, but the center crack is too much...

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BobPA

40845 BobPA https://p.vitalmx.com/photos/users/40845/avatar/c50_Engine.F_1455853935.jpg?1455853535 https://www.vitalmx.com/community/BobPA,40845/all 10/31/13 4 122 7000 10 1

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Location: PA, USA

9/26/2017 7:35 PM

Bruce372 wrote:
I had a rock in the actuator and got it welded ok, but the center crack is too much...

Agreed

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Tomac and/or Anderson for 2020.....

GarrettL

22897 GarrettL https://p.vitalmx.com/photos/users/22897/avatar/c50_96770540_1286562567.jpg?1294200986 https://www.vitalmx.com/community/GarrettL,22897/all 10/08/10 4 5 78 4

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Location: Edmond, OK USA

12/18/2017 3:19 PM

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.