blown engine case 05 wr450

6 replies to this topic
  • sausage boy

Posted August 03, 2005 - 06:58 PM


hey a friend of mine in England has just bought an 05 WR450F with 200 miles on its back, he was just trying out the kick starter to make sure it kicked over alright, when as he kicked it over it gave a little cough and a chunk of the casing blew out right where the engine number is :D anyone else had a similar problem? :D

  • flatnacker

Posted August 03, 2005 - 07:30 PM


He bought it without starting it??

  • sausage boy

Posted August 04, 2005 - 04:03 PM


he started it using the electric start.

Visit the ThumperTalk Store for the lowest prices on motorcycle / ATV parts and accessories - Guaranteed
  • YamahaWR450FMike

Posted August 04, 2005 - 08:57 PM


sure it's a yamaha that happened too? sounds like something that would happen to a Honda

  • 5valve

Posted August 04, 2005 - 10:40 PM


maybe a pic of the damage done?

  • waterdog3

Posted August 05, 2005 - 05:38 AM


my 04 broke the engine case where the kick-starter shaft rides, behind the starter. after paying $1664. "new cases,seals,bearings,and labor" the guy at the shop, while reassembling saw that a spacer was missing off of the shaft. the bike had to came from the factory like this. I bought the bike from a guy that decided a wr450 was not bike for him, 285 miles on it. Since i bought it used i never even bothered contacting YAMAHA.

  • ntreacy

Posted August 05, 2005 - 12:57 PM


OK friend... This is not uncommon. Had the same thing happen to me on a 98 WR400. Cracked the crankcase and cover. CAUSE: On removal of the kick axle I noticed a spacer missing. This had caused the axle to sit too low and miss the guide. Therefore the kick axel did not return correctly. In turn this forced the seperate kick axel 'guide' to push out against the casing. Then... destruction.
Spoke with Yamaha. Was hoping to get some encouragement.Dissapointingly they started denying this could have been thier fault. (Hadn't even accused them etc). I did a lot of investigating and dscovered that this is not an uncommon problem. Even my local Yamaha dealer admitted to seeing 4 other customers have same problem.
THE FIX? I got the main casing welded by a specialist (aluminium welder). Got 2nd hand replacement cover and re-itted the guide with a heli coil.

A real pain in the ass and I really sympathise with you on this one. But look around for 2nd hand parts. It may take time but it will be worth it.

The lesson....? Yamaha love your money but don't care for your problems. That said I did purchase a new WR450 this year (only due to unmissable bargain).Traded in with the Yamaha dealer so it was poetic.

The WR is a beast and I love it but next time its gonna be a KTM.


Join Our Community!

Even if you don't want to post, registered members get access to tools that make finding & following the good stuff easier.

If you enjoyed reading about "" here in the ThumperTalk archive, you'll LOVE our community. Come join ThumperTalk today!

The views and opinions expressed on this page are strictly those of the author, and have not been reviewed or approved by ThumperTalk.