cracked case

[kickinwing]

Yesterday at little sahara in waynoka, ok my brother cracked his case where the shift shaft goes into the tranny on is 2006 trx450r. he had a case saver and it cracked around where the bottom bolt goes in. has anyone had this happen? and what would be the best and cheapest fix for it?

in the pics we took the case saver off and the shift lever off, the pics arent very good cause i took them on my phone.

http://i1220.photobucket.com/albums/dd457/kickinwing2/clintatv3.jpg

http://i1220.photobucket.com/albums/dd457/kickinwing2/clintatv.jpg


http://i1220.photobucket.com/albums/dd457/kickinwing2/clintatv2.jpg

[Lquad71]

same thing happened to my friend. He broke his leg at one of the races from coming up short on a double and we think when he landed, he landed on the shift shaft and pushed it down and that broke the cases. That was the only reasonable explanation. He had to buy a new case.

[kickinwing]

Do you know about how much it cost him? I haven't ever had to rebuild a motor in a quad so far.

[Rich250RRacer]

Originally posted by kickinwing
Do you know about how much it cost him? I haven't ever had to rebuild a motor in a quad so far.

A case half is $235-250 depending on where you buy it. But that is a basically bare case, with exception of the clutch arm and oil pump bearings. You will need the left side crank bearing, countershaft bearing, main shaft bearing, plus seals for the balancer, crank, shift shaft, countershaft, and clutch arm. While I'm in there, I like to replace the oil pump also, since this is only accessible while the cases are split. Figure in top and bottom gasket sets, a new countershaft collar, right side crank seal, a set of rings at least ( or a complete top end depending on when it was last serviced) and a few other little odds and ends also. You should be in the neighborhood of $600-800. A couple things you should be aware of, make sure you have the CORRECT flywheel puller with the thread protector, other wise you will damage the end of the crank. I've seen this far too many times from people who unknowingly just put the puller on there without the protector, and trash a perfectly good crank. Also, make sure you have all your documentation on the quad, since Honda now has strict policy on checking VIN's before they will release case halves or frames.

[Prostart]

what is a thread protector? I am waiting on a flywheel puller and im looking for a cheap one right now, but what is a thread protector and where do i get it?

[Rich250RRacer]

Originally posted by Prostart
what is a thread protector? I am waiting on a flywheel puller and im looking for a cheap one right now, but what is a thread protector and where do i get it?

I guess the proper term is crankshaft protector. It threads on the crank where your flywheel nut would go. What it does is protect the end of the crank from "mushrooming" when using the puller. This is critical on 450R's since oil is fed from the filter into the little hole on the end of the crank. This little hole is the main source of oil for the connecting rod, and if the end of the crank gets damaged, you will cut off the oil supply to the rod. The complete tool is shown on the Motion Pro website, see the links below.

For 06-newer
http://www.motionpro.com/motorcycle/partno/08-0425/

For 04-05
http://www.motionpro.com/motorcycle/partno/08-0372/

[kickinwing]

Here are a couple better pics of the case, I think my brother is going to try and rebuild it himself so is there anything else he should know before tearing into it? Other than the Flywheel puller. He is on a very tight budget so he will prob just get a case and clean everything and put it all back in stock. he is going to get a manual and go from there.

http://i1220.photobucket.com/albums/dd457/kickinwing2/March2011039-1.jpg
http://i1220.photobucket.com/albums/dd457/kickinwing2/March2011036-1.jpg
http://i1220.photobucket.com/albums/dd457/kickinwing2/March2011037-1.jpg
http://i1220.photobucket.com/albums/dd457/kickinwing2/March2011038-1.jpg