2004 FE 450 E cracked engine case

hacker33 · Oct 13, 2014

After last ride I noticed that I had cracked engine case.
The previous owner already welded that place.
And the weld broke.
The question is why?
And whether it makes sense to weld it again?
Can be welded without opening the engine?
Engine is 9mth after rebuild.

2014%5C10%5C12%5Cbikepics-2702209-800.jpg

2014%5C10%5C13%5Cbikepics-2702414-800.jpg

zaga · Oct 13, 2014

Hi Hacker

Specially on the pre 04 bikes, the strange thing is to see a pair of cases without that crack.

You can use the engine with that crack without major problems, just check if you loose oil.

I've welded several cases, and the quality if the aluminium is a bit of a nightmare, and when you are welding, you will see oil coming out of the cases ..

You must take the engine apart to weld it, there is no other way, and you should screw the casing in to a steel plate so it doesn't twist.
After, using both casings you must check if they sit well together, if the is no gap in the back of the engine.
I have successfully corrected this problem with devcom plastic steel. Using this paste on one casing and using a good silicon spray on the other, then bolting them together. It will be a perfect match.

Finally pay attention to the torque of the axel when you install the engine back.

Hope it helps

ZAGA

bushmechanic · Oct 13, 2014

my 08 cases cracked there 3 years ago

I drilled the ends of the crack 4mm drill and sealed the area with 3bond 1207B

crack is still not going anywhere

reason I did so rather than welding is that the main loads on this area are in compression, and welding not only weakens the cases but can create stresses from shrinkage etc.

hacker33 · Oct 13, 2014

zaga said:
Hi Hacker

Specially on the pre 04 bikes, the strange thing is to see a pair of cases without that crack.

I have cracked cases... Don't worry it's normal

Cool! Nice to hear it

For me it's big broblem because oil leak very well. I ride supermoto and dripping oil on the rear tire does not bode well.

I have in my garage epoxy called "liquid metal" and Wurth 250 engine special silicone. I try to seal it using these two materials.
I also found on the ebay used cases from 2004 450 in good condition. I will buy them just in case.

Thanks guys!

spanner · Oct 14, 2014

Good to drill holes as Bushie described or the crack will get longer.

hacker33 · Oct 14, 2014

spanner said:
Good to drill holes as Bushie described or the crack will get longer.

I do it! Thanks

zaga · Oct 14, 2014

Hi

I've ride for some time with the same problem. To seal it I've used a very common thing, but I don't know how it's called in English. Basically it's one kind of silicon that is very common in constructions, it is a sealer and a glue. That is how it's commonly called here "sealer glue". I will try to find one that you can compare.

It's better to use one thing like that because it's flexible, the liquid metal it's hard so probably will break under stress. You know under load the casings will rub against each other

ZAGA

Taffy · Oct 14, 2014

i have a set of 450 cases here fella

regards

Taffy

edelweiss · Oct 14, 2014

I can help you with good cases from 400 2002, u would have to do the sem-kokusan conversion, but they would not cost you a lot of money.

hacker33 · Oct 15, 2014

I have an offer for 140 Euro with shipping to home. Cases from 450 2004.

edelweiss · Oct 15, 2014

thats a good offer if the cases are absolutely ok.

zaga · Oct 15, 2014

Hi hacker

I have her one example for you about the glue and seal that I was talking about.
For example this wurth MS instant. It's one example of one good that I've used.

ZAGA

hacker33 · Oct 17, 2014

Ok. I put 3 layers of epoxy to aluminium.
I wonder how many can withstand

2014%5C10%5C17%5Cbikepics-2703329-800.jpg

hacker33 · Oct 19, 2014

I still wonder why the engines brokes in this place.
It's possible that the frame is too flexible and the cases brokes after some jumps?
Thats way DCR and other teams make that strenghtening on the bottom on the frame.
Like in this picture:

zaga · Oct 19, 2014

Hi
I don't think that they do that because of the engine cases.
The cases are a bit weak, not with a fantastic aluminum qualaty.
If we had another support in the head zone, like the japs, maybe the problem would go away

Cheers
ZAGA

Highflyer · Feb 12, 2015

Hi.
I'm cuddeling with my newly bought FC 550, '01, and giving it a service while I'm waiting for the snow to let go. Unfortunately I've found the same crack on my case, like yours, hacker33.:cry:
How did your fix worked for you? Did it hold up?

I have Devcon as mentioned here.

hacker33 · Feb 12, 2015

It did not help.
I bought a used engine cases.
I will also stiffening frame.

Highflyer · Feb 13, 2015

hacker33 said:
It did not help.
I bought a used engine cases.
I will also stiffening frame.

:cry::cry::cry:

Anybody knowing excactly what models to look for, and what to do to prevent a new one to crack?:unsure:

zaga · Feb 13, 2015

Hi

I think after 04, the cases are better.

I've sent the casings to a good welder and they are good now.

To prevent it from happening again, check the cases gap at the back end of the engine and correct it with the procedure I've described earlier. I also only torque the pivot axel to 100 N.m, and I check it from time to time.

ZAGA

johnyberg · Feb 13, 2015

All '04 cases suffers from cracking, i have 2 pairs of 650 with a crack at the main bearing area. Dealer said to me that '04 cases had this problem and husaberg fixed this from '05-'08 models. The solution is simple... change the cases from later model.

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