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Dirt Bike Kick Lever Repair

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  • Dirt Bike Kick Lever Repair

    One on my vintage dirt bikes needed its kick lever repaired.
    On the down stroke the lever made of cast aluminium stops by making contact with the steel foot peg.
    As you can see they get pretty torn up.

    Ji
    Attached Files
    Grip it and Rip it

  • #2
    First run of weld.
    Had to support the end as it started to get droopy.

    Ji
    Attached Files
    Grip it and Rip it

    Comment


    • #3
      After a quick sanding the lever looks good.
      Ready to start the bike again.

      Ji
      Attached Files
      Grip it and Rip it

      Comment


      • #4
        Originally posted by Jigantor View Post
        After a quick sanding the lever looks good.
        Ready to start the bike again.

        Ji
        Looks great..!!

        what did you use for filler??

        welding machine and settings??

        post weld heat treat??

        am sure there are many members in a similar situation that would be very interested in the details...
        .

        *******************************************
        The more you know, The better you know, How little you know

        “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

        Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

        My Blue Stuff:
        Dynasty 350DX Tigrunner
        Dynasty 200DX
        Millermatic 350P w/25ft Alumapro & 30A
        Millermatic 200

        TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

        Comment


        • #5
          For cast I always use 2.4mm diameter 5356 filler.
          I think the lever was forged so heat treatment most likely will not help much. Just let it cool naturally.
          Power wire brush to remove all contaminates.
          Machine setting,
          No pulse
          100 argon
          1.6mm diameter Lanthinated electrode
          9 cup on a 9 torch
          25% balance
          3 seconds pre gas and 15 seconds post
          I set amps to max and use a foot peddle so no idea how many amps
          Pre heat with the torch.

          Ji
          Grip it and Rip it

          Comment


          • #6
            Thanks!!!

            always nice to have the how with the what...

            that'll help someone down the line...
            .

            *******************************************
            The more you know, The better you know, How little you know

            “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

            Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

            My Blue Stuff:
            Dynasty 350DX Tigrunner
            Dynasty 200DX
            Millermatic 350P w/25ft Alumapro & 30A
            Millermatic 200

            TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

            Comment


            • #7
              Hope it helps.
              I could have spent hours carving it into its original shape but there is no point as it will only get torn up again by the foot peg.

              Ji
              Grip it and Rip it

              Comment


              • #8
                Originally posted by Jigantor View Post
                Hope it helps.
                I could have spent hours carving it into its original shape but there is no point as it will only get torn up again by the foot peg.

                Ji
                Looks like it will get the job done just fine...

                Out of curiosity... what brand and model welder??

                pics??
                .

                *******************************************
                The more you know, The better you know, How little you know

                “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

                Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

                My Blue Stuff:
                Dynasty 350DX Tigrunner
                Dynasty 200DX
                Millermatic 350P w/25ft Alumapro & 30A
                Millermatic 200

                TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

                Comment


                • #9
                  Kennametal is not real quick in my country.
                  Had to wait two weeks for them to get me a lathe tool holder and insert that is in their latest catalogue. In the end I gave them alternatives and they produced the alternative I suggested but the inserts for the first tool holder.

                  Anyway when I did get the right lathe tool I turned a stainless steel bolt down to the Yamaha specs for the kick starter knuckle pin.

                  Ji
                  Attached Files
                  Grip it and Rip it

                  Comment

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