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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 12 Jun 2020
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Yamaha xt600e 2003 dj02 crankcase right broken
hi I have a Yamaha xt600e 2003 dj02

and my crankcase the right side is broken, I want to know if I can use crankcase from earlier years like 1990 or 1986, because I don't find newer.
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Old 12 Jun 2020
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I must be blind - I can't see where it's broken. I DO see casting marks which might look like cracks. Can you put an arrow where it's broken?
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Old 13 Jun 2020
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in the second picture I draw a black line, there is where is cracked


I am disarming the engine, to see if I can weld it, but I prefer to put a crankcase. if I can use one from a earlier model it would be great, I cant find a 99-03 one. on eBay I just found 84, 88, 90. and some are expensive.
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Old 13 Jun 2020
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look in the yellow circle
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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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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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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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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 16 Jun 2020
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Quote:
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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