1997 501

huskyksi · Oct 13, 2012

i have got a 1997 501 kick start only engine fitted in an eltric start frame i took the swing arm out recently to re place the bearings i noticed that the engine case had broken behined the swing arm pivot bolt is this a common problem,
as apart from the pivot bolt and the bolt under the engine that is all what holds engine in place.

Bergini · Oct 14, 2012

I have seen other ones with a broken case in that area, but dont think it is a really common problem, i would guess its from bolts getting seized and being stubborn when removing, people prying on the engine case to remove from the frame or swingarm, or broken when splitting the cases for bottom end repairs.

if it is a kick only engine in a estart frame i beleive that the engine mounts are different, a kick only would have two plates at either side on the front of the engine and the swingarm pivot bolt, an e start engine has one 12" or so long smaller bolt that mounts toward the front of the engine like the swingarm bolt would at the back of the engine and does no have the plates, i would guess in your case the front engine plates would need to be custom made and could hold the engine in the frame under tension and could have caused the breakage but in my opinion more likely it was already broken prior to it being installed in the frame.

welcome to the site, be sure to change your oil and filter very frequently, you have a nice bike it you take care of it :cheers:

Bergini · Oct 14, 2012

wait a sec, if you just have the bolt under 2 long mount bolts are you sure that it was a estart that was converted to kick only, maybe i am wrong about how they mounted with the estart/kickstarts being different......
you could check the vin number on the right hand side of the steering head and find out for sure then compare to the infor in the owners doc. to get to the owners doc there is a button on the top left side of the home page, although its kind of irrelevent info as to why the cases broke, you may find out its not a true kick start only engine but actually just had its e-start parts removed.

tinwelp · Oct 14, 2012

All,
I've a 2002 Fe400e which had the same cracked cases issue as described. I cannot speak for what the former owner had done (he just said it started to leak oil and he'd had enough... starting problems, naturally), but when it came to me with a leaking case nothing was siezed and there were no signs of butchery in the area. Once clean, the crack welded up a treat.

Someone must've had a serious 'off' at some point in the past on mine as the subframe has been straightened and welded. I don't know if this had anything to do with the cracked cases. The cases remain perfectly oil-tight five years after the repair, so I wouldn't be chasing a set of cases for no reason.

Cheers... Paul

huskyksi · Nov 3, 2012

Bergini said:
wait a sec, if you just have the bolt under 2 long mount bolts are you sure that it was a estart that was converted to kick only, maybe i am wrong about how they mounted with the estart/kickstarts being different......
you could check the vin number on the right hand side of the steering head and find out for sure then compare to the infor in the owners doc. to get to the owners doc there is a button on the top left side of the home page, although its kind of irrelevent info as to why the cases broke, you may find out its not a true kick start only engine but actually just had its e-start parts removed.

your right about the plates as previous owner had made some plates but they where quite crude and only made to pick up on lower single point. and the earlirler point is no the swing arm pivot was not sized as i had it out eirlier in the year to grease and it was a bit tight but a tap with a hamer and brass drift it came out.
i have fabricated some proper plates from aircraft alloy and i will weld 4 round spacers to the 2 frame rails that are just in front of the engine, and that 12" long bolt was £12 8O 8O 8O and the left hand thread fly wheel nut was £6 :shock:
It's definatly a kick start only engine as i have the e start engine in bits and a replated barrel also that came in the box of bits apart from the cracked case and a few bearings for the swing arm linkage its been a great bike from Ebay

jampe · Nov 3, 2012

Yes.
That`s a common problem with the cracks, have 3 engines 400-501 99-00 that all are welded there.
Regards
Jampe

zaga · Nov 3, 2012

Also,
I have 2 engine with the same problem, both welded, one is olding, the other is opening again ???

[attachment=0:1rr9uci8]400_02_case_weld.jpg[/attachment:1rr9uci8]
[attachment=1:1rr9uci8]470_01_case_weld.jpg[/attachment:1rr9uci8]

:cheers:
ZAGA

1997 501

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