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Message started by KLM on 05/11/21 at 14:13:17

Title: Engine Case interchange
Post by KLM on 05/11/21 at 14:13:17

On tearing down my basket case '86, I discovered that there was a nice sized hole in the bottom of the crankcase. The po had covered the hole with a load of some kind of semi hardening sealant. I'm wondering if I can transfer the internals, which all look good to any year crankcase halves or if I need to stick to a specific year range.

thanks

Title: Re: Engine Case interchange
Post by Dave on 05/11/21 at 17:24:20

I believe you can use any 4 speed engine cases.

That should be from 1986 to 1992.

There is a belief that the 1986 model had a primary and clutch gear ratio different than the 87 and later bikes.......I am not sure anyone has actually documented that - or if the difference only shows up in the parts manual.

Title: Re: Engine Case interchange
Post by verslagen1 on 05/11/21 at 18:00:14

I don't know what the differences are, but there are a few.
Maybe not the case, you should examine them closely.

A while back, someone wanted to exchange the final drive shafts, but the ones they had gotten where different and didn't fit.

So I'd rather buy a complete lower end, case and guts.

Title: Re: Engine Case interchange
Post by Hiko on 05/13/21 at 01:29:19

There are people around who can make permanent repairs to engine castings

Title: Re: Engine Case interchange
Post by Dave on 05/13/21 at 02:12:20

If the bike was mine and I was going to be putting miles on this bike - I would make the upgrade to a 5 speed engine. Be sure to move the rotor and stator from your 86 onto the replacement engine so the timing and electrical connectors are compatible. You will also need all the transmission internals as the gearbox is different.

Title: Re: Engine Case interchange
Post by KLM on 05/13/21 at 10:40:17

Thanks for the info everyone. I definitely have some options to weigh.

Update:

I had already ordered a set of '97 cases from eBay when I posted this. Figured I'd have to return them. Spent the weekend dry fitting everything. No issues discovered yet. All the lower end parts fit and seem to be working fine. Started final reassembly today.