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August 15th, 2005, 12:02 PM   #1
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FE400 engine case cracked, 2001

A friend of mine rides a 400 FE. It has been flawless so far but now their are signs of a crack around the swingarm area. I have seen this on the forum before. Anybody have expirience with welding it without opening the engine (as we had planned to do)?
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August 15th, 2005, 12:26 PM   #2
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i had a crack in my fe600 right case but not at the swingarm area. it was located under the flywheel area, it had about 6cm of length and oil was coming out in large quantity from the crankshaft chamber. i just welded it and i had no further problems-it is been a year or so since then.
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August 15th, 2005, 01:09 PM   #3
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Hello Jeroen,

I had a very long crack in the right side case of my 2000 501. The welding caused the case to warp slightly, and it had to be surfaced. They removed about 0.010" (they did not measure it).

I never considered trying to have them weld it with the motor assembled.

Other than causing a mainshaft bearing to fail in about 7 hours do to the axial preload caused by the surfacing of the case, the weld held and has not leaked.

I guess the shop did not think to check the transmission shafts clearance. I had a subsequent falling out with them, and rebuilt it myself. I corrected for the dimensional change by extending the spline on the shaft.

Pictures of the cracked case and the subsequent bearing failure are in my Gallery.

Regards,

Joe
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August 15th, 2005, 02:07 PM   #4
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If you stitch weld it (short bursts) and
keep the heat down it should work.
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August 15th, 2005, 06:41 PM   #5
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I had a 2001 Fe400 in the shop today that had a oil leak at the left side of the swing arm area.I suspect it has this same issue.What is the cause of these cracks in this area? ......nsman
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August 16th, 2005, 01:50 PM   #6
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Thanks guys. I know welding as such isn't going to be the issue but doing so with closed engine. I wonder if there will be tension in the case when it will be welded with all parts in place.
I remember you had it also Joe but I already thought you opened the engine for this.
If I am correct the 2001 models had this problem and were strengthened around this area as of 2002. Next to this there could be several things that can cause something like this; not enough slack on the chain, a rock between chain and sprocket has the same effect. But a loose swingarm bolt could do the trick also.
I will take it to a welder during the week and hear what he has to say.
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August 17th, 2005, 12:26 AM   #7
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the problem is oil contamination in the crack. that's why welded cases rarely if NEVER work....

regards

Taffy
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August 18th, 2005, 10:03 PM   #8
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Hello!


I had the same problem with the case-crack around swing arm area at my FE400 '01.
I fixed it with liquid epoxy (Loctite or similar) and it works. I grinded the crack with a Dremel a bit deeper and wider, cleaned it with a detergent and filled the crack with the epoxy. Also the area beside the crack were coverd a bit with the material. It's good now for more than a month, and I know another Berger who did it the same way and had no problems for two years until he sold his FE.

I think, welding is an expensive and time assuming alternative.
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August 21st, 2005, 07:54 AM   #9
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Will a set of 02 470 cases replace a set of 01 400 cases?
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August 21st, 2005, 03:46 PM   #10
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According to my parts manuals, YES, they are the same part number.

Joe
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