Die Cast engine cases

[Hawkeye]

I haven't studied a new Gasser up close, do they still have sand cast engine cases? Big potential weight savings to be had if they are still sand cast. I weighed a clutch cover off of a 2002 300XC which was sand cast, and then weighed a die cast one off of a 2005... The sand cast weighed 12 oz. and the die cast weighed just 8 oz. I was surprised at the difference, it was just a little clutch cover. Imagine a couple pounds could be saved on the center cases by getting them die cast. Then there is that swing arm, it is really thick!

[ruckusman]

They use different alloys - sand cast alloys are actually less brittle, die casting can be more dimensionally accurate, but tooling costs more

Magnesium cases are lighter, but much more fragile...

Casting in itself is a huge topic and usually there's no one single perfect solution for all aspects

[Hawkeye]

My guess is it is probably a cost issue. Back in 2003 I was at the dealer intro and was talking to a guy that was responsible for R&D back at the factory. We got to talking about the rather cobby look of the engine castings, and he laughed and said "You should see the appearance of the cast blanks we get from the supplier before we machine them!"

That being said, the quality of the aluminum in the cases is top notch. Clean and pure compared to the Japanese alloys. My Yamaha's cases looks like someone emptied their ashtray into the crucible before pouring them!

[GMP]

Still sand cast. I have no problem with that. For a woods bike that will take more abuse than typical motocrosser, I'll take a little extra weight for the durability.