Dirt Bike Kick Lever Repair

[Jigantor]

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

[Jigantor]

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

Ji

[Jigantor]

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

Ji

[H80N]

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...

[Jigantor]

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

[H80N]

Thanks!!!

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

that'll help someone down the line...

[Jigantor]

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

[H80N]

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??

[Jigantor]

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