Difference in Engine 450-510 Cases between '05 and '06?

Can anyone tell me definitively what the difference in engine cases was between '05 and '06 for the 450-510 motors?

I have looked at the parts fiches and know that they have different part numbers but I cannot see what the difference is between the two years. Something in my mind tells me that the '05 cases are smaller in one area than the '06-'07 cases but I can't put my finger on why that is in my head.

I thought the main difference between the '05 and '06 450-510 variant motors was in the heads and not the cases.

Any ideas? Trying to find a replacement set of cases for an '06 motor that I have and not having any luck finding '06-'07 units. Found a set off an '05 and hoping I can make it work.

Thanks

Joel

I'm not sure but wasn't 05 the last year of the counter balance shaft? I would call at George at Uptite.

My '06 has the counterbalacer so I'm not so sure that is the difference. Did they change something up around where the kick start lever goes into the cases?

Thought they were the same

Got some confirmation from Jeff at Halls that they did in fact make some pretty big changes up around the kick starter area. Other than that I'm pretty much certain that the remaining internal parts will work. No kickstarter being an SM510 so shouldn't have to worry too much just make sure I get the right gasket kit.

Joel

The kickstart assemblies are different. The SMs have balancers all along, the TEs discontinued them after 2005. The primary ratios were different from 2005 to 2006. The valves aslo grew a bunch in 2006 as well.

Why did they stop balancing the TE's?

I never saw a reason for it, probably cost reduction and a quicker revving engine.

I forgot to mention the 2005 engine also holds less oil.

Makes sense to me

Curious how this is the case seeing as the case halves are similar on the lower part of the engine and only until you get to the area up around the kickstarter does it change. Not saying you're wrong just trying to understand how.

I put the balancer into my 08 when we rebuilt it, after removing the boat anchor pressed on crank mass weight I swear the thing revved quicker and is 100% more smooth with the CB shaft assy. After installing the CB shaft I asked a hundred times why the F they removed the C'B from any of these models. Including the TC (probably).

My friend now owns the 08 TXC450 with the C/B shaft assy, its such a better bike its just miles above the OEM set up. The 08 TXC cases were still cast with all the C/B shaft assy bosses and the parts were @ $200 total. The thing is so smooth and causes way less fatigue when riding it.

If you have the cases split I highly recommend installing the CB shaft assy, also I recommend weldin the thing onto the crank as it is a press fit unkeyed set up (bad engineering IMHO for a driven weighted assy), we put 4 tack welds on after we aligned the gear in the crank then filed them down to clean them up.

Bigger clutch cover.

That is what I was going to say. And I don't think there is a big difference, 150cc?

Ahh I see. When you say clutch cover are you talking about the right side engine cover or the smaller round cover that directly covers the clutch basket?

My 08' idles almost like a (gulp) Harley. I don't ever want to see a SMR cause I will probably want to split my cases!

I think it is 200cc.

I know this is an old thread but does anybody know if it is possible to install the counter balancer assembly in a 2009 TE 450?

Yes it is.

go into the parts catalog and view the SM counterbalancer assy parts, I have no idea if you can still get these parts, but thats how I did when I rebuilt my 2008 TXC450. the retail parts cost was under $300, a couple drive gears the balance shaft and a couple of bearings, it was an easy installation as far as engine building goes. but I do 100% stand by reengineering the crankshaft mounted drive gear by welding it to the crank so it cant slip.