Cracked Case

[polaris24]

I'm new to the jet ski world and new to this site but wow there is alot of great information on it. I'll get to the question at hand. I have just recently purchased a 1992 SL650 and there is a crack in the upper case on the exterior wall of the cooling chamber. I was wondering if JB weld could be tried on this or would that be just to difficult to seal with? Is there any other concern with the engine with this leak or would it just be the concern with water leaking into the hull? I'm not looking forward to have to tear the engine apart and get new cases but if that has to be done then so be it. Any suggestions would be appreciated!

[Keddano]

Can you get a picture? It's probaly from water freezing in it. Clean the area good and maybe grind it some so the sealer will adhere good,Instead of JB Weld, I'm use a 2 part marine grade putty. The cooling system isn't under real high pressure,so it shouldn't blow the putty off. I'm running one repaired like that right now with no problems.

[polaris24]

I've attached a picture of the crack. I think you are right that water was left in there over winter and froze and cracked the wall.

[beerdart]

I think I would be worried about the cylinder base leaking. If it were me I would pull it down and investigate.

[starflight]

I think the bigger problem may be that its posible to have cracked internally as well. I'd pull that cylinder to inspect the inside.


Damn, I'm slow.

[polaris24]

Thanks for the responses! The engine seems to run fine and the compression is good, so I was thinking that if there was damage on the internal wall there would be other issues but that might not be the case?

[Keddano]

That's about were mine was,But wasn't pushed out that much.If You did the repair with the jug off the you could make sure the surface is smooth for sealing. I'll bet you look close and you have more cracks in the other ones too.

[starflight]

Are we looking at a jug there? If it was a jug I would change it. I'm having a hard time placing were it's at. How much water is in that hull,looks like it's deep in there.

Its cracked under the jug.

[ZMANN]

the 92 is one of the only blocks that has water circulate thru it! they eliminated the lower cooling and went to just filling the cylinder jackets in later years

[K447]

the 92 is one of the only blocks that has water circulate through it!
they eliminated the lower cooling and went to just filling the cylinder jackets in later years

Is there any connection inside the engine between the cylinder water jackets and the crankcase water jacket?

Can this be repaired simply by removing and capping all the water hoses feeding the crankcase cooling loop, and running it without ANY water flow into the crankcase?