2004 FE 450 E cracked engine case

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IF....I want to look for a replacement case-part, what model can fit?

I believe there is short, medium, and high cylinder, depending on what ccm?

I think I might want to use it as is, and try to reduce/stop the oil from leaking. I might want to look for a replacement case-part, and change it when/if I'm going to have a full service on my engine.
 
It depends from the cc of your bike, 450 are the short ones, 550 are medium and the 650 are the tall. If you are going to buy another pair of cases you should look for '05-'08.
 
It depends from the cc of your bike, 450 are the short ones, 550 are medium and the 650 are the tall. If you are going to buy another pair of cases you should look for '05-'08.

My bike is a FC550/4, '01. I was first wandering if I could find a new right side case-part, like mine.....uncracked, and switch it. But, do you mean that a complete crank case from a '05-'08 will fit all my interior parts and side covers?:unsure:
 
hacker wrote
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?
There would be quite some stress in this area one would think.

There appears to be some wear on the steel bush that the swinging arm bolt goes through. This would indicate to me that perhaps the bolt has at some time not been tightened up properly and is quite common on some of the cases I have seen.
There should be no movement here to create such wear.

This area that cracks is perhaps where the 'cold shot' ends up during the casting process, it looks as if there is a riser (overflow vent in the mould) in this same area, ie the lug near bearing seal. So there may be a combination of causes.

I have been looking closely at 2004 cases vs 2005 onwards to see if there is much
difference...

The 2005 has a boss on the right hand side for the crankshaft locking bolt, although it
is not drilled for the 450`s
The water transfer holes to the head are different near the exhaust area, ie a slot
instead of a single hole.
The 2005 onwards has the oil squirter.
The part numbers are different.
Can anyone add to the list of differing features?

Some claim the main bearing area is stronger, I can not see any evidence of this???

Cheers spanner
 
The cases after '04 has an oil jet at left side for better piston lubrication, bigger holes for water circulation, and the main bearing area is stronger. I have 2 sets of '04 cases with a crack at the main bearing area.
 
I have 2004 and 2005 cases from 450.
So let's go:

1) Bigger water transfer holes in 2005. 6mm holes vs 6x12mm slots.
2014%5C03%5C19%5Cbikepics-2652534-800.jpg

2015%5C07%5C20%5Cbikepics-2750424-800.jpg


2) Bigger cam chain holes in 2005. 20mm vs 21mm. The chain does not touch the wall.
2015%5C07%5C20%5Cbikepics-2750407-800.jpg

2015%5C07%5C20%5Cbikepics-2750406-800.jpg


2015%5C07%5C20%5Cbikepics-2750410-800.jpg

2015%5C07%5C20%5Cbikepics-2750411-800.jpg


3) 2005 has a oil nozzle. 2004 only tight channel.
2015%5C07%5C20%5Cbikepics-2750419-800.jpg

2015%5C07%5C20%5Cbikepics-2750420-800.jpg


4) 2005 had more material removed around gears by a milling machine.
2015%5C07%5C20%5Cbikepics-2750412-800.jpg

2015%5C07%5C20%5Cbikepics-2750413-800.jpg


2015%5C07%5C20%5Cbikepics-2750414-800.jpg

2015%5C07%5C20%5Cbikepics-2750415-800.jpg


2015%5C07%5C20%5Cbikepics-2750417-800.jpg

2015%5C07%5C20%5Cbikepics-2750418-800.jpg


There is no variation around the mainbearings and around the output shaft!

If the 2005 cases does not crack, in which case:
- may change cases material?
- it is the result of a new stiffer swingarm and the swingarm bolt?
 
hacker says
There is no variation around the mainbearings and around the output shaft!

I agree as far as I can tell from the photos I was looking at as well.

hacker says
If the 2005 cases does not crack, in which case:
- may change cases material?

This is a possibility.

Would love to see some photos of the cracked main bearing areas.
 
this thread is helpful, I had my fe 450 stripped 6 months ago and I'm still waiting for the machines to machine the oil squirt addition into my 04 crankcase, fortunately iv had no cracks but i still haven't had my casings back so wondered if anyone had a set of 05 casings for sale so I can get it rebuilt and use it again?

Cheers for all the help though!
 
this thread is helpful, I had my fe 450 stripped 6 months ago and I'm still waiting for the machines to machine the oil squirt addition into my 04 crankcase, fortunately iv had no cracks but i still haven't had my casings back so wondered if anyone had a set of 05 casings for sale so I can get it rebuilt and use it again?

Cheers for all the help though!

but that is a 30 minute job fella?

Taffy
 
yh the place that's doing it are taking the piss! can you recommend anyone that's used to doing it taffy??

cheers
 

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