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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 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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  #2  
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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  #3  
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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  #4  
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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  #5  
Old 15 Jun 2020
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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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  #6  
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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  #7  
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 15 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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  #9  
Old 16 Jun 2020
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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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  #10  
Old 16 Jun 2020
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meanwhile, please let me ask this question.
Quote:
Originally Posted by Mezo View Post
It is non repairable, my 600E cracked in the exact same spot, ...
- does that mean that it's something like a "weak spot" of the engine? pretty concerned about it...
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Old 16 Jun 2020
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first time i ever seen this type of failure and i run some heavily stressed XT based engines in my supermono and supermoto,



doesnt mean it cant happen, as we see.


im always more interested in the "why?"


one reason i can think of is heavily lugging at low rpm, but not that provable.


when you take the motor appart, check the right main bearing fit in the new cases, if its too loose, that could be another reason.
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Old 17 Jun 2020
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Originally Posted by turboguzzi View Post
first time i ever seen this type of failure and i run some heavily stressed XT based engines in my supermono and supermoto,



doesnt mean it cant happen, as we see.


im always more interested in the "why?"


one reason i can think of is heavily lugging at low rpm, but not that provable.


when you take the motor appart, check the right main bearing fit in the new cases, if its too loose, that could be another reason.



ok, thanks I will check.
I used the bike as everyday ride for 2 years, and after 3 months of buying it I rebuild the engine, but dint change the timing chain, so in august last year I put the timing chain new, and I used to ride everywhere in Dominican Republic, and I was about to sell the bike before the engine started vibrating when you rev it, I thought it was a bearing but the right crankcase is cracked almost breaking part.
I am still waiting for the mechanic to disarm the engine
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  #13  
Old 16 Jun 2020
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Originally Posted by N67 View Post
does that mean that it's something like a "weak spot" of the engine? pretty concerned about it...
Well if its going to go, it will go around that area as all the ones ive seen have done so right in that same spot (around the balance shaft) my 600E, a 3AJ Tenere & a TT600 Belgarda.

And there have been a couple of catastrophic failures in the same area due to the balance shaft key sheering & then that just detonates the engine case.

I wouldn't necessary cal lit a "weak spot" if everything is within spec & maintained its a strong engine, but if something goes wrong (bearing, key way etc) that is where the case will fail.

Mezo.
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Old 17 Jun 2020
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Quote:
Originally Posted by Mezo View Post
Well if its going to go, it will go around that area as all the ones ive seen have done so right in that same spot (around the balance shaft) my 600E, a 3AJ Tenere & a TT600 Belgarda.

And there have been a couple of catastrophic failures in the same area due to the balance shaft key sheering & then that just detonates the engine case.

I wouldn't necessary cal lit a "weak spot" if everything is within spec & maintained its a strong engine, but if something goes wrong (bearing, key way etc) that is where the case will fail.

Mezo.
got it. thanks a lot.
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  #15  
Old 18 Jun 2020
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Quote:
Originally Posted by Mezo View Post
Well if its going to go, it will go around that area as all the ones ive seen have done so right in that same spot (around the balance shaft) my 600E, a 3AJ Tenere & a TT600 Belgarda.

And there have been a couple of catastrophic failures in the same area due to the balance shaft key sheering & then that just detonates the engine case.

I wouldn't necessary cal lit a "weak spot" if everything is within spec & maintained its a strong engine, but if something goes wrong (bearing, key way etc) that is where the case will fail.

Mezo.

Mezo, not really following you here... the crack in Traians case is around the main crank bearing, not the balancer shaft.... are we talking the same failure here? or is it just my bad eyesight? started wearing reading glasses lately...
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