JB weld on crankcase casting defects

[JZ05220r]

As a lot of you know some Kawasaki models are notorious for having casting issues on the left crankcase. There are three recesses in the crankcase around the crank seal area, I circled them. The aluminum at the bottom of each recess is extremely thin and just behind it is a steel liner that’s built into the case for retaining the crank bearing. Many have performed leakdown tests and couldn’t find the source of the leak until checking below the flywheel……This is on my 91 200. Noticed a fuel smell under the stator cover and there is absolutely no sign of a crank seal leak. However I suspected that it had to do with porosity within the casting indentations around LH crank seal/bearing. Decided to go ahead and JB weld it. Came out good, but you don’t see it anyways. My one regret: I didn’t scratch up the surfaces much before applying. Hoping it lasts the life of the engine. And hopefully this is the cause. If so, the smell would’ve taken a long time to build up because it was dry as can be. I had that cover sealed pretty well with the addition of RTV on the stator grommet.

[KDXGarage]

Good job. KX60 needed that, too. It is in an Eric Gorr book from 1996 that a portion used to be on his website.

[JZ05220r]

Good job. KX60 needed that, too. It is in an Eric Gorr book from 1996 that a portion used to be on his website.

Thank you!

[billie_morini]

JZ, please describe more thoroughly or annotate the photo to indicate the location(s) that epoxy was applied. I cannot determine this and do not know the content in the referenced Eric Gorr book. Thank you in advance. billie

[KDXGarage]

It is somewhat depressed. It is where the steel "pocket" or whatever it is called is from the other side that holds the main bearing. There is an occasional bit of porosity on the E models. Fredette used to say to seal it up. I can't remember if it was in the Kawasaki dealer newsletters or not (K News I think it was called).

EDIT ADD ON: K Tech News

[JZ05220r]

JZ, please describe more thoroughly or annotate the photo to indicate the location(s) that epoxy was applied. I cannot determine this and do not know the content in the referenced Eric Gorr book. Thank you in advance. billie

No problem, I updated the original post, thanks for the feedback!

[Chuck78]

E-Series and H-Series crankcases are the same, I believe identical part #'s even (it's just the clutch case area and top end that are completely different E-Series vs H-Series).

So yes, the H-Series also needs checked or just epoxied in this area as well.

[billie_morini]

JZ, thank you for annotating your original photo. Now this Old Man is wiser!