Clutch cover repair

[60something]

As I work through my '87 KX500 rebuild, I have yet another question. As I see with many KX500s, my clutch cover had the ol' brake pedal-jammed-into-the-clutch cover damage. Whoever had the bike before had welded it, but it leaks oil around the welds. I'd like to have it look better than the mud-dauber welds that it now has. There is a product out there; some "aluminum solder rods", that are supposed to be the cat's meow for repairing aluminum. Has anyone tried these? I was thinking I could grind the old welds down and then go over it with the aluminum solder, then smooth that out. On the other hand, my number one priority is just to have it leak-free. If I do have to have it rewelded (I wouldn't weld it myself), is there any advice on ensuring it's done right?

[Sandblaster]

I've tried those rods and they can work under perfect conditions.
The big issue is getting the working surfaces clean enough to adhere.
You would have to remove the garbage welding, and bake it to remove all the oil that you can.
You need to get the aluminum hot enough to melt the rod...
DO NOT use the torch to melt the rod.
Of course a good tig guy can repair a cover in a few minutes

[60something]

Thanks Sandblaster.
Apparently whoever welded these cases wasn't too good at it
Guess I'll give the aluminum solder a go. I can always grind the whole mess down and take it to a welder if it doesn't work right.
I'll post the results.

[60something]

...which brings up another question...is there a way to keep the brake lever from busting up the case again? I mean beyond not crashing
Like some sort of case guard?

[Sandblaster]

Not that I have ever seen.
That is one of the reasons why I developed a two piece clutch cover for the KX500.
That way I could just replace the outer cover and be done with it



If you have a drill press you can make one at home.
All you need is a 1/2" end mill that will fit the chuck size of your drill press.
A drill bit and a tap for a M6 x whatever bolt size... I think it is a 1.25... Better double check.
A 06-16 KX450F clutch cover.
A piece of 1/4" aluminum plate... Bought mine on eBay...
A buddy that can tig weld aluminum..
And have fun...

https://www.youtube.com/watch?v=X-gkWTEL7aI

[60something]

Thanks, I saw that in my searching for solutions. Wow, everything about that bike you posted is beautiful!

[60something]

P.S. Your case cover is a great idea, and very well done! Maybe next winter...