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  1. #1
    Join Date
    Jul 2009
    Location
    Australia
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    Default 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
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    Grip it and Rip it

  2. #2
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    Jul 2009
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    Australia
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    Default

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

    Ji
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    Grip it and Rip it

  3. #3
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    Jul 2009
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    Australia
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    Default

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

    Ji
    Attached Images Attached Images
    Grip it and Rip it

  4. #4
    Join Date
    Nov 2003
    Posts
    3,150

    Thumbs up

    Quote 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

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  5. #5
    Join Date
    Jul 2009
    Location
    Australia
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    Default

    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

  6. #6
    Join Date
    Nov 2003
    Posts
    3,150

    Thumbs up

    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..

  7. #7
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,031

    Default

    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

  8. #8
    Join Date
    Nov 2003
    Posts
    3,150

    Thumbs up

    Quote 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..

  9. #9
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,031

    Default

    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 Images Attached Images
    Grip it and Rip it

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