Cracks in axle holder
 

While cleaning up the front end of my '97 XT I noticed these hairline cracks on the axle holder. I'm not aiming to cut corners on a bit that keeps my front wheel where I like it to be, but the only place I've found a replacement is MSP where the cost with P&P is going to be 50 euros. This seems excessive for a small slab of alu so I wondered if anyone has had any success with welding or repairing these? The cracks do not show on the underside but are clear to see on the top side.
http://www.horizonsunlimited.com/hub...1&d=1535668024

Buy new, you dont want to have front wheel coming off one side.

https://www.ebay.co.uk/itm/YZ250WR-Y...cAAOSwZrdbPA5v

That comes from tightening the cap wrong . If you look at how the cap and fork leg boss line-up you'll see the top of the cap is meant to sit flat and the bottom is where the tightening occurs . The mating surfaces aren't in line with each other so when tightening a different way creates a bending pressure on the cap which breaks them . That's the reason for the "up" arrow.

Maybe a dismantler will have and bent fork with a good cap , otherwise new is all there is if you can't make one .

Biggest problem is that alot of homemechanics think they have torque wrench in the arm and overtighten or underthighten screws and bolts all over, this one is only 10nm and i bet this one had alot more pressure and wont crack at 10nm.

BTW it was sale on the holder i gave link up here, so its a bit more expensive now.

I had one of my XT`s with exactly the same crack, toss it in the bin & do not think of welding it.

Mezo.

The bike was pretty trashed when I got it and every stage of the rebuild has thrown up some example of bad treatment by previous owners. The front end is the last stage though so hopefully the last unexpected expense. Amazing what you find once you get the corrosion off. I've found a Yamaha original at Wemoto which is cheaper with more sensible postage so will be going for that. Thank you as always for the replies and the expert insights you guys bring to this site.

Didnt know they had original parts like that, send link so others can use it.

It's https://www.wemoto.com/bikes/yamaha/xt_600_e. I've had stuff from them a few times in the past and it's always worked out great. The site is not great for searching though - I'd already looked there for this part (and not found it) until I thought of searching by part number.

One of few parts they have same price as OEM, good thing is they remove VAT and have cheap shipping. Other parts are more expensive so compare before buying.

Please Note: Prices are in British Pound (£). Delivery charge to your country is an estimate, we will contact you if there is a difference in price.

Don't try and repair it. Welding aluminium isn't as simple as puddling a bit of metal along the crack. The grain structure changes and becomes brittle alongside the weld and will soon break again. Get a new one if possible, uncracked secondhand otherwise, and tighten it as jjrider said.

possible fit ,

https://www.ebay.com/itm/YZ250WR-YAM...dbPA5v&vxp=mtr

Same as my link..He already bought new from wemoto.

Just reopening this thread - I recently discovered similar cracks on the axle holder on my 34L XT600Z with 4PT forks.

Found this aftermarket replacement that I’ve ordered - https://titanclassics.com/product/al...-3xj23167l000/

The WeMoto part is no longer in stock.

Ed


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https://uploads.tapatalk-cdn.com/202...b139f7964a.jpg

You can just make out the hairline crack below the top holes, about 80% across from the left and above the bottom holes, about 30% across from the right.


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Thanks for the update!

Lots of people above are saying you can't weld aluminium ... that hasn't been my experience, however you do need to get someone who knows what they're doing.

fixing
 

Tension, compression or torque and Mailability are a concern with aluminum, welding can be done if static like a case cover has no stress
this Problem is a trunnion cap crack 4 bolts it secures the axle and the axle is none rotating
it is highly unlikely the axle will ever come off Look at the meat on this thing
You can't Weld Aluminum especially cast that has lower radius tolerances than the axle tolerance it is called a friction fit that make the trunnion grip the axle
dont weld buy new
look after your moto and it will look after you
this is typical manufacturing mistakes that pass quality control You have to look at the whole picture when working on bikes there are many defects that you are not aware of this one needed a shim or washer and its obvious to have a grip on the axle
bikes are not made well But there are exceptions You get what you pay for Try Aircraft maintenance it is in a another league

If that came to me for MOT I would slap a dangerous fail on it and make it illegal to ride home.

Replace that ASAP..

It could be welded. But you would have to grind down to the beginning of the crack and built up in layers.. And that would cost more than a new cap for it to be done properly.

Welding it - And then, would you REALLY trust it with your life, and your wife's life?
Totally agree with Ted, REPLACE with NEW - or there's a link to a better one that looks like a great idea since the OEM is clearly flawed.

Interestingly enough, I looked back at some old photos from this time in 2019 and the same cracks are there, albeit not as long. The bike had only been ridden a handful of times since then, however, as it'd had a prolonged stay at David Lambeth's for an engine replacement.

I was high up in the Pyrenees in Spain when I spotted them, two weeks ago.

I did chew over getting it welded or even whacking a load of JB on there, just to get me through the last 7 days of the trip and back to the UK.

I decided against both in the end because a) either option would mask the crack, meaning I couldn't see if it continued to increase and; b) it seemed like too great a risk.

I parked up in a nice spot and got a replacement part sent from OffRoadCentrum in Holland via DHL Express, which worked as I fancied a day's rest anyway! I was good to go 48 hours later.

This used OEM part is an interim replacement - I've now received 2 x aftermarket replacements from Titan, which I'm going to fit to both my XT600 34L and 3TB as a precaution.

They certainly look well machined and look the business!

Ed