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Old 07-28-2014, 07:39 PM   #1
byron555 OP
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Location: Central Wisconsin
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WR250r split case...



Broken case
The welding and epoxy idea has crossed my mind. The spot is in a non-high stress area. However it is the gasket surface and I was worried about it sealing. In addition the lower mounting stud for the case saver sheared off. There is a 99% chance that the broken chunk is in the engine. The chain broke with a hell of a lot of force, my back tire locked up at about 72 mph for a moment, stalling the engine. I hit the clutch immediately, which did nothing and the chain snapped, The tire started rolling again and I coasted to a stop.

It broke in a strange fashion, I don't think any case saver stock etc, would have saved the case. The Sandman saver is a little tweaked, but I am sure I can straighten it. The lower spacer and bolt from the saver fell into my skid plate.



I was using a 14t sprocket, which reduces clearance and my have contributed. The chain by all accounts looked pretty good, and was cleaned and oiled regularly. I think one of the links on the inside was bad, and the long uninterrupted miles got it hot and it seized. It broke the plates on both sides in the middle of the link, not at the pins. The rivet master link was fine

I have order an array of Tusk tools from Rocky Mountain ATV. Case splitter, Clutch basket tool, fly wheel holder and fly wheel remover.

The 08 WR450f uses the same fly wheel remover I found out.

In the end, what I take away from this experience is: Chains are cheap, and no matter how well you take care of them, replace them after 8,000 miles on this type of bike ( mine gets used off-road fairly regular and in lots of sand). My chain had 12,000 on it... It still looked good, very little stretch, but what I could not see did the bike in. It was a Primary Drive brand chain.



Ok, the engine is out, so is the swing arm, tank and all side body work.




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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633

byron555 screwed with this post 07-28-2014 at 07:46 PM
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Old 07-28-2014, 08:03 PM   #2
byron555 OP
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on my re-build

by no means is this a comprehensive expert rebuild... I just don't want to be "that guy" on Craigslist that states, "all the parts are there, ran out of time, $2,200 cash" You know the type... ask thousands more than a $900 project.

What I want, need, in this thread is: experience, share your technical excellence with us all. You have split a case on a WRr??? great share the knowledge. The problem is that this bike is so DAMN reliable that there is very little info on line as how to repair them.

KTM... no problem the orange folks know what to do... this is no KTM, it is a lard ass, reliable Yamaha owned by Lazy-Folk, with kids that have other interests (stupid bastards) like soccer, etc... Hey I try, see that XR50, idle in the background
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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-29-2014, 07:57 AM   #3
byron555 OP
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Stator cover cracked too

Add another $88 bucks to the damage... I am not surprised the cover cracked, it really was not noticeable until I removed it



Here is the case damage from the inside, the crack extends an inch down the case. The whole section is bent in a little.

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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-29-2014, 08:31 AM   #4
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That sucks big time,its good your taking it apart. Sometimes having an engine stop/bang at speed like that can damage internals. Best to check everything out real close when apart,gears.etc.
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Old 07-29-2014, 09:30 AM   #5
justlookin
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Did this job about a year ago to my WRR. If you have ever split the cases on a four stroke - really no tricks to this engine. Take pictures if you need to - align crank and cam marks and take picture so you remember how the cam lobes face correctly. Also as you go in with crank at TDC get a pic of the counterbalance alignment before you remove it Pay attention to the manual on reassembly of the cam chain tensioner - it takes a little fiddling the first time. I bought factory gaskets and seals - don't know if any aftermarket sets avail. Check bearings carefully while you are in there - 2008 - maybe 2009 used a different countershaft bearing - I am aware of a catastrophic failure of that bearing - a lady here on ADV - early bike. Mine is a 2010 with 50k miles so although mine felt fine I changed it for piece of mind.
Early on in my bikes life I broke the chain and caused the same damage - to a lesser degree - no pieces inside but stator cover was the worst. I watched Ebay and found all the pieces for cheap - fixed with epoxy and rode while I waited - yours with pieces inside - I would be tempted to see if I could account for all the pieces and repair with epoxy - these are tough engines. Good luck
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Old 07-29-2014, 09:47 AM   #6
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More progress

Removed the clutch side cover, I left the oil filter and water pump in place



I removed the counter balancer shortly after snapping this pic.



I am at a point now where I will be needing special tools. I am taking my time, labeling bags with what fasteners are in them and so on
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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-29-2014, 10:46 AM   #7
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Back around the mid-70's, my dad and I once repaired an old Honda XR75 in which I cracked the case in the same manner. We used JB-Weld and whatever pieces and chunks of the case that we could find and that thing was still holding together when we sold it 25 years later.
Degrease the parts well, mix the JB-Weld like it says to mix it (1:1 ratio), take your time, file/dremel/grind to fit, and I'll bet it'll hold forever.
For the gasket sealing surface, smoot it down by laying some wet/dry sandpaper on a flat surface such as a marble countertop (you can get plenty of throwaway pieces from your local fabricator) and lay the whole case on it to grind it down smoothly. Take your time.
It'll turn out fine.
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Old 07-29-2014, 12:26 PM   #8
what broke now
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"flat surface such as a marble countertop"

Great idea...budget surface plate.
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Old 07-29-2014, 12:40 PM   #9
Soldier311
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Quote:
Originally Posted by what broke now View Post
"flat surface such as a marble countertop"

Great idea...budget surface plate.
Yep, I use it to sharpen my chisels and plane irons too.
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Old 07-29-2014, 04:30 PM   #10
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While I appreciate the jb weld idea, and if I was stuck some place I would do it. Its at home, and to be honest, I am really enjoying working on th motor. We will see how I feel in a wek or two. If all goes well it should be back on the road in august.
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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-29-2014, 04:44 PM   #11
byron555 OP
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Oh and I did find the piece in the case
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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-30-2014, 08:51 PM   #12
byron555 OP
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The case is split

Well I got the case split. It went pretty smooth. I noticed before I got too far that I did forget one case bolt on the left hand side near the cylinder base gasket, and I lost the woodruff key on the crank for the flywheel magnet thingy (technical term) when I was pressing the crank out. It seemed pretty solid when I tried to take it out prior, but the pressing must have loosened it








The hone marks from the factory are still there... pardon the slight dust, I wiped that out with a rag.

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WR250R... 15 cubic inches of raw power.
WRr re-build
http://www.advrider.com/forums/showthread.php?t=997633
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Old 07-31-2014, 04:45 AM   #13
Soldier311
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That's amazing that the hone marks from the factory are still there.
How many miles on that engine? And, hell, just to start a post-fest, what kind of oil have you been using?
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Old 07-31-2014, 07:28 AM   #14
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Pretty amazing you got the cases split with just two empty beer bottles.
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Old 07-31-2014, 12:48 PM   #15
what broke now
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Quote:
Originally Posted by montesa_vr View Post
Pretty amazing you got the cases split with just two empty beer bottles.

They look like harbor freight beer bottles, too.
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