Maintenance & Technical > KX500 Original
2 piece clutch cover
RoostiusMaximus:
welding these pieces, I've been able to have s junk main case handy so I bolted the clutch case to it, do what you can to clamp it on something flat. If the cover has had a previous ding in it then it'll be twisted to start with.
Don't try to clamp the ring down to the work bench etc. The heat from the welding will distort the case. If you need to hold it to get it tacked on then do it with a c-clamp or something that won't follow the case like a visegrip etc or it'll keep compressing until the case cools down.
I bake the case on a hotplate until I can tap out the governor bearing, not so that the bearing turns blue. The case should sweat out what oil it has absorbed and be much cleaner welding.
Start near the governor area, its the thinnest so do it before it gets too hot to work with. move counter clockwise so you end up at the heaviest portion of the case last.
should go smooth.
sandblaster:
Thanks for posting that info.
Mine turned out ok with not a lot of warpage but I made a steel ring to bolt it to.
I'll try your method next time and see how it works out.
vagassasson:
Yeah it is kinda low on my to do list atm. I have to rebuild the crank in both my motors before anything else and right now I'm just waiting on rebuild kits
Candyman:
I need pictures :cry:
--- Quote from: RoostiusMaximus on December 09, 2014, 01:52:17 AM ---welding these pieces, I've been able to have s junk main case handy so I bolted the clutch case to it, do what you can to clamp it on something flat. If the cover has had a previous ding in it then it'll be twisted to start with.
Don't try to clamp the ring down to the work bench etc. The heat from the welding will distort the case. If you need to hold it to get it tacked on then do it with a c-clamp or something that won't follow the case like a visegrip etc or it'll keep compressing until the case cools down.
I bake the case on a hotplate until I can tap out the governor bearing, not so that the bearing turns blue. The case should sweat out what oil it has absorbed and be much cleaner welding.
Start near the governor area, its the thinnest so do it before it gets too hot to work with. move counter clockwise so you end up at the heaviest portion of the case last.
should go smooth.
--- End quote ---
RoostiusMaximus:
They're working out pretty well. We did 4 lastnight, changed the clamping procedure of things to zero. :roll:
The welder said he was getting 60-65 amps in it to puddle the pieces, only added minimal filler rod. The case finished flat, I did warp a mounting ear by .040" or so on 2 of the covers but installed them on a case half, warmed them and tapped them down with the brass hammer and they're perfect.
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