KDXRIDER.NET

Hi! new member here. First of all thanks for the help you guys give on the forum, it was really usefull for me when looking at used kdx on sale.

My problem is as follows, i got a pretty decent 1994 kdx 200 a few days ago, i brought it home and noticed that the oil level was low, added half a liter only to wake up the next day to a huge oil spill. After looking at the crankcase i realiced it has a big crack on the left side behind the front sprocket starting from the seal.

I already found a replacement from a used 1992 kdx 200 anybody knows if it is the same one? It looks like it from the pictures.

Or would you try tig welding it?

Sorry for any gramatical mistakes, english isnt my first lenguaje.

Thanks in advance!

Martin.

Assuming you are in the US, and working on an E series, then yes, it is the same one.

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I would TIG weld it & buy the replacement part, but then, I have a TIG welder in my garage. If you were close, I could fix that for cheap, if you do the cleaning.

Thanks! I bought the replacement and will probably try to weld the old case just to see how it goes, i do own a tig welder but im not confident on my aluminum welding abilities ( think the case is made of cast aluminum?).

Really apreciate the help!

Regards from Argentina.

Martin-vereert wrote:Thanks! I bought the replacement and will probably try to weld the old case just to see how it goes, i do own a tig welder but im not confident on my aluminum welding abilities ( think the case is made of cast aluminum?).

Really apreciate the help!

Regards from Argentina.

I can help you with your Aluminum welding with a TIG. I weld aircraft parts for my job. If you want to try welding the case 1/2, get it super clean. I mean really clean. Remove all, and I mean ALL the oil out of the cracked area. You will need to press out that bearing, it's just a heat sink, the heat will destroy the bearing.


You need to stop drill the crack.


We can talk about welder setup. You must use Argon for shielding gas. A/C current. I would use ER 4043 filler rod.


Remember, clean, clean, clean are the first 3 rules for welding aluminum.
Keep in touch.

Did you buy a matched pair of halves or just a left side?

Molly's 70 wrote:

Martin-vereert wrote:Thanks! I bought the replacement and will probably try to weld the old case just to see how it goes, i do own a tig welder but im not confident on my aluminum welding abilities ( think the case is made of cast aluminum?).

Really apreciate the help!

Regards from Argentina.

I can help you with your Aluminum welding with a TIG. I weld aircraft parts for my job. If you want to try welding the case 1/2, get it super clean. I mean really clean. Remove all, and I mean ALL the oil out of the cracked area. You will need to press out that bearing, it's just a heat sink, the heat will destroy the bearing.


You need to stop drill the crack.


We can talk about welder setup. You must use Argon for shielding gas. A/C current. I would use ER 4043 filler rod.


Remember, clean, clean, clean are the first 3 rules for welding aluminum.
Keep in touch.

Thank you so much! I will keep in touch, i want to make sure the new case will fit first. If it doesnt i dont want to take any chances and will take the cracked case to a pro welder.

Jason wrote:Did you buy a matched pair of halves or just a left side?

One side only, please dont tell me it wont align correctly

Dice roll
Let us know if you crap out.

Jason wrote:Dice roll
Let us know if you crap out.

What are my chances? I didnt made the payment yet, which one is a safest bet in your opinion? Welding the crack or buying one side?
I could buy both sides actually but it will cost me almost half of what i paid for the bike (1200 usd for the bike plus 250 usd for one side only)

Just for reference, imported goods here cost nearly twice as much than in the US

Can you just buy some halves?

I have bought 1994 halves for under $100 in the USA

Jason wrote:Can you just buy some halves?

I have bought 1994 halves for under $100 in the USA

I bought (didnt actually paid him yet) this half from a guy who is selling his bike by parts, i could posibly buy the other matching half as well but it doesnt make sense because of how much i would have to pay.
If you guys confirm me that i need matching halves i will probably just try welding it.
I simply cant pay 500 bucks for 2 used halves.

Thank you all for your replys so far!

Damn. $500. I have bought E parts bikes for less than that.

I always have been told these are matched cases. I would take the chance.

Jason wrote:Damn. $500. I have bought E parts bikes for less than that.

I will probably wait for someone who doesn't sell his parts for the weight in gold.

Molly's 70 wrote:I always have been told these are matched cases. I would take the chance.

Taking my chances welding it or buying only the left half? Sorry if im a bit slow haha

I bought a set of matched case halves for my 89 for much the same problem. I was able to find a matched set for under $100. I do have an intact left side I would let go of if you want to take your chances with just one side. Problem is that the mating surface for the jug is machined with the case halves bolted together, so that mating surface may not be even with mis-matched halves.

https://www.ebay.com/itm/Crankcases-Lef ... :0&vxp=mtr

He has the year model year fitment wrong, but says it was pulled from a 91 so it would work for you.

Julien D wrote:https://www.ebay.com/itm/Crankcases-Lef ... :0&vxp=mtr

He has the year model year fitment wrong, but says it was pulled from a 91 so it would work for you.

Thanks for both replies!! I need to figure out the cost of the shipping + taxes, probably wont be cheap.

I just came from a bike repair shop, the owner told me he made countless cases swaps with no trouble at all, including Kawasakis, but that he is aware of the probabilities of a case not aligning correctly (just what you guys have been telling me).

Anyway i will buy half a case and tell you how it went.

Regards!