welding 200s engine case :-(

[PAPA250r]

ok so my 1984 200s developed a stress crack near the front motor mount about 2 inches long and its leaking oil .

can this be welded ? or should i just start looking for a diffrent bottom end ? thanks in advance for any info or stories with similor repairs . ;)

[Dirtcrasher]

Were you missing or running a loose bolt or mount??

I can't see why it would "stress crack", something else is going on or it hit something.....

If it's the main case and oils coming out, good luck. It's contaminated which Tig welding doesn't like.

I know you don't want to take it all apart, so lay it on the side for the day, scuff it up and JB weld that puppy and keep an eye on it!

[yamaha driver]

i recommend using jb stik Works on all metals. OR jb water weld which is better for fluid areas. so much easer than the two tubes. and they are about 5 bucks a stick at fleet farm.

[Russell 350X]

I would try the JB weld aswell...sounds like your best bet..

[STiForester]

i would lay it on the side and thoroughly clean it... than scuff and tig weld it... if you have to jb the weld.. but thats just me I'm a certified welder and yes it won't like the oil but seriously clean it and i would do both

[RacerRichie]

sand scuff up the mating areas use brake clean before the JB good luck bra!

[Thorpe]

I would gouge the crack out with a die grinder, clean with brake clean, and tig... Done dozens on dirty oil tranny cases over the years with good success...

[Dirtcrasher]

^ Then you sir, are a good TIG welder :beer

We still need to know WHY the crack formed. Hondas don't get stress cracks in the motor castings, they break frames.......

[STiForester]

i welded my clutch cover on my tecate when the kicker broke through... check out my tecate build pics... works great, but yes you need to see why it cracked in the first place or it may do it again..... maybe even a different spot

[PAPA250r]

It is quite possible something hit it but i didnt see any dents or marks near the crack.

Thanks for the sugestions i am going to pull the motor and see if i can weld and /jb weld it :( hope it works engines been real reliable even with high compression piston never let me down

[bugler30]

It can't be that hard to find a good case I wouldn't think as those are always having transmission and flywheel key problems.

[PAPA250r]

well i picked up a mint case on ebay for 30 bucks. ..... now if i can only purchase the motivation to swap them ..lol

[PAPA250r]

the saga begins decided to swap the case .

[atc350xer]

Good luck! It always looks so intimidating to me, but a good shop manual goes a long way.

[Dirtcrasher]

Good luck! It always looks so intimidating to me, but a good shop manual goes a long way.

He's already on the right path, nice clean bench, clean parts and well organized :beer

[PAPA250r]

Thanks :-) ! I do love my repair manual thats for sure I wasnt looking foward to this at all but so far everything going nice and smooth with the exception of a overtightened clutch bolt that gave me a hard time . Ha to fab up a home made sprocket holder and use a ton of man power lol

[atc350xer]

Thanks :-) ! I do love my repair manual thats for sure I wasnt looking foward to this at all but so far everything going nice and smooth with the exception of a overtightened clutch bolt that gave me a hard time . Ha to fab up a home made sprocket holder and use a ton of man power lol
That's why I keep a 4' length of 1 1/2" iron gas pipe around... it can convince any bolt to come off :lol:

[PAPA250r]

making some good progress. just waiting for the 2 oil pump screws i had to drill out to show up should be running by friday :twisted::twisted::twisted::twisted::twisted:

and only a 12 pack of beer invested so far...lol

[PAPA250r]

all done fired right up no issues no leaks .... :twisted::twisted::twisted::twisted:

time to ride .

[RacerRichie]

Way to go. Rip it up !

[jb2wheels]

Nicely done - that's a big project that would retire an ATC for a lesser owner ;)

[Dirtcrasher]

Yes, very nicely done, you ought to be proud of yourself!!

[PAPA250r]

Thanks :-). !!!! Me and this atc been through a lot lol was a very willing subject