Hey all, I need to weld up a hole in the case of a '82 XT200 and was wondering if anyone has suggestions on the proper TIG filler rod and temp to use, as well as the composition of the alloys used to make that year's cases? I think the case broke when a chain broke and whipped a hole in it near the front sprocket. The engine came off a shelf at a junkyard. Thanks!

Case or cover? early 600`s of that era used magnesium covers (its written on them).

You cannot alloy weld magnesium covers, must use magnesium.

Mezo.

Case.

I’ve seen “Magnesium” cast into the case covers of the 600’s before so i know it’s a thing, i just dont know for sure if it’s a thing on this bike.

If so it is only the covers, not the engine cases.

A friend has successfully welded things like that on XT600 cases using AlSi5 oder AlSi10.
I would think that the XT200 alloy may be similar.

Could you take bits of the broken spare engine case as filler? Not so easy to work with, but surely the same material.

Andy

https://forum.millerwelds.com/forum/wel ... ycle-cases
interesting read
I have had cases welded in the past although not a perfect look the repair ws reliable.