Bought a XR650R

3 replies to this topic
  • mmrizio

Posted December 24, 2006 - 08:05 AM


Hi All,

I just bought a XR650R so my KTM520EXC doesn't have to make so many road miles. I picked up a reasonably well example, but there are some 'fixes' by previous owners that I am not so happy with.

Main annoyance is that the chain must have snapped, taking with it the chain 'catcher' above/in front of the sprocket. Problem is that the top mount of the bracket broke off as well. And the previous owner has drilled the hole to try and mount a new bracket. He drilled it fully through to the inside of the gearbox area. Can I just block the hole with a bolt? Should I worry about oil lines in that area?


  • motopsycho650

Posted December 25, 2006 - 08:50 AM


Ouch. Not the best situation in the world, by far. At one point on my bike, the lower mount on the engine case cracked in 3 places around the threaded hole. I was able to find a local aluminum welder and he was able to repair the cracks. He ended up completely filling the hole, added some extra metal around the outside, and re-drilled & tapped the hole. Great fix, but he charged me 100 bucks. I would try looking into this idea.

I hate to say it, but if that was my bike, I would probably tear it down & replace that side of the case. Not a fun prospect, but if the damage is as bad as it sounds, anything less would bug me.

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  • mmrizio

Posted December 25, 2006 - 12:23 PM


Hi Motopsycho. Your email worries me, but I hope it is not as bad as you fear. It is only the external rib that broke, just about flush with the other extension. I don't think there was any damage to the rest of the casing, as the casing is a series of ribs with a lot of strengths. The bottom mount joins the casing at a flat side wall, a big hit will much easier crack the casing. I wasn't worried about that part. Should I? Do you think the casing will crack? I had similar damage on my old LC4 that never gave me any trouble.

What I was more worried about was the 'fix' by the previous owner. In a vague attempt to remount the bracket, he drilled the old hole with a smaller diameter drill. He drilled all the way into the innards of the gearbox. When I inspected the damage, I saw some holes belonging to the internal oil system near the clutch area. So I got worried whether he damaged some internal oil lines.


  • 76Datsun280z

Posted December 25, 2006 - 12:35 PM


Let's see a picture of you new bike!

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