Not a Good Weekend!!

[cr2504life]

Well, I was planning to take my cr apart this weekend for a rebuild. I was going to replace piston, rings, needle bearing, crank bearings, and a bunch of other things. Well my buddies were all getting together to go for a ride on Saturday so I figured that the bike could wait until the first of the week before the rebuild. Well we went out all day and on the way home (long straight dirt road) I was riding beside a friend on a 400ex and the bike bogged down and quit. I just figured the piston let go so I wasn't too mad. I got it home and cleaned it all up, and while I was draining the oil I noticed a big hole in the crankcase. :bang: I figure that a rock must have flown up and put a hole right in it. So now I have to buy a new case among the other things. The crank bearings seized up solid but I'm hoping that it never totaled the crank. I know now that when I, well if I get it fixed im not driving it again until I get a good skidplate. :clue:
Well hope you guys had a better weekend than me :ugg: . lol

PS Also if anyone knows a way to repair the cases please let me know.


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[Ol'89r]

PS Also if anyone knows a way to repair the cases please let me know.
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cr.

A good tig welder should be able to repair it. In most cases you don't even need the pieces.

If you can, post a picture of it.

 

[cr2504life]

I had no idea that you could tig weld the cases. I'll post a pic tonight if i can. Do you think it is possible even if it is broke right at the seams? Just one half is cracked I think.

 

[Ol'89r]

Do you think it is possible even if it is broke right at the seams? QUOTE]

It may require a little machining after it's welded, but it can be done.

 

[cr2504life]

Once I get it apart Im going to try to find a shop that can try to repair it. That way I don't have to fork over too much cash for a new one. It could be a while before I get it fixed because university is hard on the budget. Damn I hate being in school.

 

[GETMETOCA]

If you have trouble posting a picture let us know and you can email it to one of us and we'll post it for you.

 

[cr2504life]

By inspecting the hole close I have come to the conclusion that the hole was caused by something inside and not a rock.

 

[dirt bike dave]

cr2504life - if you were flying down a road and backed off the throttle w/out pulling the clutch in, the hot motor is still turnign high rpm, but has no lube or cooling fuel. The big end bearing probably went out, and with all the extra play in the rod wore a hole in the crankcase. That's what happened to my '99 engine.

For mine, a crankcase repair was possible but may have cost $100+. For Honda CR250s, you can buy the crank case halfs individually (around $160 I think from Service Honda) and the new crankcase half will have a crankshaft bearing installed in it (approx $30 part); so it might be cheaper for you to buy a new case. BTW, for the CR250 you can also get a new crank assembly (crank/rod/big end bearing) for about $160 and a new piston & top end kit will be about $120. Add in a gasket set $70+, a second crank bearing ($30) and a few odds and ends ($50) and you are looknig at about $600 for parts, plus tax and shipping; more if you need both crank halfs. If you are going to do it yoruself, you will need a shop manual and special tools, as well.

The prices I mentioned are US$, and not full retail like you might have to pay at your local dealer.

 

[Ol'89r]

Once I get it apart Im going to try to find a shop that can try to repair it. QUOTE]

cr.

That is a good idea. Check with the shops in your area and ask them if they have a welder that they could recommend. Check with all the shops not just Honda shops. Also, if there are any automotive race shops, they might be able to steer you in the right direction.

Like Dave said, Service Honda is an excellent source for parts.

If all else fails, PM or e-mail me. We did one here in my shop about two months ago similar to what you are describing. It had a hole about the size of a quarter punched out from the inside. Tig welded it and blended the inside. Cost to the customer was $45.00

The broken piece was intact. Just had to knock it out, grind and clean it, weld it back in and blend the cases. :cool:

 

[cr2504life]

Thanks to all of you who have replied.

 

[Treejumper]

I busted the bottom half of my case out with the chain. It took from the shifter hole down out. A guy at a local machine shop welded it shut and machined the holes back in it for the shifter shaft. Works great and other than them grinding it smooth you wouldnt know it was there. He did it for $100 and that included the gaskets for the case and a new shifter shaft.

Finished repair

Attempted JB weld fix at Dirtweek 01' (worked til you tried shifting) :)

 

[cr2504life]

WOW, they did a great job. I had no idea that they could fix severly damaged cases like that. Im going to call some local shops to see if they will do it for me. Thanks