1983 XC 250 Engine Cases

Upon tear down of my 83 XC250, I found a crack in one of the web gussets on the left hand engine case that supports the crank bearing. Which model years XC, WR etc, use the same cases as the 1983? First Husky so any advice appreciated.

The other option is to see if anyone local can repair the case. There is no leaking currently but I can foresee this being a future problem. Anyone have experience with this?

The 250cc in '82, '83, cr,wr,XC and ('84 wr only) cases are interchangeable.

The only other option is to weld it. By drilling a small hole at the end of the crack both ends, dremel the vee in the crack and tig weld it with magsneuim rod.

why are you excluding the water cooled units? 82-86 250 cases will work for this. 87-88 the crank case is a tiny smidge bigger but could likely still be used.

The LC cases have the larger diameter swing arm bolt.

yes the only diff are swinger bushings..they can be heated and swapped

only the later w/c's, the 84 - 85 have the small swinger bolt bushes

Only on the single shock application because of the change to a 14mm swingarm pivot. The twin shock applications were 12mm swingarm pivot. The set of 84 250CR centercases confirmed this.

Thanks guys for all the replies. Good info. My welder says he thinks he can tig weld it but I will have to wait and see once I deliver the cases to him. I may be looking for a set of engine cases depending upon the outcome.

tig not work unless you use ERAZ92A rods.
mention these to your welder....hold adhere better

I used certainium alloys & research company TIG rod for magnesium welding. I got a sample rod from my vendor.

A Penton enthusiast sent me some az101 magnesium filler rod. He has had good results welding vintage KTM cases so my welder is up for trying it.

I weld magnesium parts in a cardboard box with the argon gas turned up on the TIG welder. The magnesium must be completely surrounded in argon gas otherwise it will start on fire. Don't step on the weld droplets on the floor. One looks like Richard Pryor running down the street if you try to put him out you will have ten or more of him running away. Don't ask me how I know this. Just let the droplet burn out. I welded magnesium on a acorn welding table. The droplet fell through the square hole in the table.