As far as I know there is a known way to make the zstart from a DRZ400 along with the stock clutch pack and a 2 piece clutch cover work. I recently saw that Rekluse makes a torqdrive clutch pack, which is essentially really thin drive and friction plates. I thought if they turned out to be thin enough the 2 piece mod might not be necessary. Through research I found that a '08 KX450's clutch plates are the same as a KX500's. I ordered Rekluse's radius x for a '08 KX450, which is the torqdrive clutch pack as well as the exp 3.0 disc.
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Stock clutch pack width is 33.9mm and the torqdrive clutch pack is 23.56mm. Looking good
Only problem I faced was that there was no gap between the clutch plates when all the plates and exp disc were installed, so what I did was simply put a washer between the little cap that the push rod pushes on and the pressure plate, that was the only thing I had to do.
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I put some grease on the heads of the pressure plate bolts and put the clutch cover on then removed it and checked the inside for grease, there was none, so I know they aren't touching, how much of a gap there is I don't know.
Another problem I encountered was that the radius x kit only came with 5 pressure plate springs whereas the KX500 uses 6, I'll have to see if I can order another one from Rekluse. I don't think it would be a good idea to use the stock springs as they are not designed to work with an auto clutch.
Let me know what you think, thanks
, Engine Ice, and many many more.