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2004 250kxf Blown lower casing where kick start gear is can that be welded?

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Not easily and the cause is more concern than the damage, I have done the same thing and tried easy fixes that were a waste of time and then put my bike in to be fixed properly.

Posted on May 08, 2013


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You need to open the side cover on the kick starter side. Check if the spring that returns the kick starter ha snot came out of his position. There is a hole in the casing that it must hook into, that hole sometimes crack or break open then the spring locks in between the gears. I had mine welded up and I drilled and tapped the hole, bent the spring side ways and bolted it down, it has not came loose yet. If the spring is still in its position, remove the clutch plates and see if the engine has not seized up.

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Huskt tc250 broken inner an outter case round kick start

Obviously, new casings would be the best option, but another option you have is to take the parts to a commercial welding shop and have them Heiliarc weld the casings. Alternate to that, you could try Googling motorcycle salvage Husqvarna to see if you can get some used parts. The bad thing about a busted inner casing is that you should change out the inner casings as a matched set. Sometimes the casings don't line up perfectly if only replacing one side and the result is shafts that freeze up when you tighten down the screws. Please rate my answer. Thanks.

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Have a Johnson 130 leaking gear oil on bottom of foot and bottom full of water

What year model? Tools you will need. (1)gear case pressure tester from any outboard dealer. why buy and not build. matching the threads on the drain plugs.(1) detergent and water in a spray bottle. troubleshooting step (1) Remove lower unit from engine as if you were changing the impeller.(2) secure lower unit in a holder so you can drain oil and do visual checks.(3)remove drain plug and vent plug, drain oil(4) reinstall lower drain plug and put pressure tester into vent plug hole(5) pressurize gear case(6)with spray bottle spray gear case at all seals and joints just like you would spray a tire looking for a leak. detergent will bubble at leak.(7) if you find leak at a seal were you will need to remove drive shaft or propeller shaft you will have to buy removal tools and a Clymer repair manuel from your local dealer.(8) hopefully the leak is at the shift shaft or the drain and vent plugs so you wont have to buy special tools to replace seals.(9)if you find a crack in the case have it welded at you local outboard dealer

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Kick start broke and case broke

the kick start broke or did the shaft that the kick start bolts to?, if the shaft broke, you will need to remove the case and replace the shaft. as for the case, depends on how bad it broke, some people can weld alum. but i would buy a new case. and then install kick start on new shaft

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Have broken the chain on a wrf 250 03 model and managed to take a small piece out of the casing adjacent to the front sprocket. Seams to have exposed a small oil capillary feeding the gear box. Any...

I am unaware of any oil capillary by the sprocket. The only thing in that area not fully exposed to gear box oil is the left end of the shift drum. There wouldn't be enough friction on the drum to need any oil not already provided by the gear oil.

I would suggest the following > Drain the oil and then remove the sprocket and then thoroughly clean up the area around the sprocket and the break. Take the bike to a local welding shop. They should have a MIG or a TIG welder which will weld the casing. After the welding is done ,install a new oil seal on the output shaft.

The above suggestion is the low cost way to get by. The proper way is to replace the casing, preferably as a matched set of upper and lower case halves. If you get just the bottom, ( or top ), half you run a serious risk that the shafts may bind when bolted together. Replacing the lower casing is not all that big of a task. Replaceing the top casing is a pretty big job because the entire top end has to come off as does the crankshaft, clutch, gears and shafts, shift drum and electrical. Major project and NOT for the novice or the timid. You could Google ' motorcycle salvage yamaha ' and get the casing(s) or get the entire gearbox or the entire engine.

It's your decision how far to carry the repair. Personally, I would weld the box. It is a low cost and easy thing to try. Worst case is that you wind up replacing casings. Hey, the weld was worth a try!

Please rate this solution. Thanks!

Mar 27, 2009 | 2003 Yamaha WR 250 F

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Nissan Exa gear problem

Dear Customer,

As you said above your engine oil is goin lickage so find out any crack or pinhole on pipeline for collent oil rails.

replace oil pipies weld any crack found on transmision case thna your gear will work batter.


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