KX450F VS KX500 CLUTCH BASKET COMPARISON

[Sandblaster]

KX450F VS KX500 CLUTCH BASKET COMPARISON
Wouldn't it be nice to be able to get a brand new KX450F Hinson clutch basket and drop it into your 89-04 KX500?
I would sure like it...
So, what would prevent you from doing it?
Let's see..
Here is a pic of both baskets side by side.

KX500 VS KX450F CLUTCH BASKET 101.JPG (129.28 KiB) Viewed 16191 times

KX500 VS KX450F CLUTCH BASKET 102.JPG (45.52 KiB) Viewed 16191 times

[Sandblaster]

Right off the bat, the KX450F basket which is on the left has a much smaller bearing hole then the KX500 Hinson basket on the right.
However, when you drop the bearing and the collar into the center bearing hole of the KX500 basket, the KX500 Basket has a smaller hole size.

The KX450F ID measures 25mm

KX500 VS KX450F CLUTCH BASKET 103.JPG (64.63 KiB) Viewed 16190 times

The KX500 ID measures 22MM

KX500 VS KX450F CLUTCH BASKET 104.JPG (73.13 KiB) Viewed 16190 times

[Sandblaster]

So the ID of the bearing holes are different and the gear's are clearly different.
What about removing the basket off the KX450F and mating it to the KX500 gears?
Let's see...
Here is a pic of the KX450F basket.
The mounting bolt hole circle is 8 bolts on a 93MM bolt circle.
Also, the basket diameter is 157mm.

KX500 VS KX450F CLUTCH BASKET 105.JPG (74.47 KiB) Viewed 16190 times

The KX500 mounting bolt hole circle is 8 bolts on a 96MM bolt circle.
Also, the basket diameter is 153mm.

KX500 VS KX450F CLUTCH BASKET 106.JPG (61.92 KiB) Viewed 16190 times

[Sandblaster]

So, no joy there.
Is it possible?
Sure, with enough time and effort anything is possible but is it worth it?
But I think I would get a Mitaka before that much effort.

http://www.mitaka.co.uk/KAWASAKI%20CLUTCHES/4389.htm

Mitaka clutch kx500.JPG (28.12 KiB) Viewed 16190 times

So, what about the clutch plates, hub, and pressure plate?

[Sandblaster]

On the left is the KX450F Inner clutch hub.
On the right is the KX500 Inner clutch hub.

KX500 VS KX450F CLUTCH BASKET 107.JPG (117.71 KiB) Viewed 16188 times

The KX450F hub has larger and fewer splines.
Also the KX450F has less springs and bolts which might give you a lighter clutch pull but I wouldn't risk it on a KX500

[Sandblaster]

So pretty much a bust except the metal and fiber plates which do seem to be the same on both bikes.

[dirk_411]

I got to reading this. I'm in the same boat with my tecate 4. I can use the k5 basket which I am, the hinson. I want a full hinson set up. I don't have any parts at my disposal like you but from surfing images I was wondering if you were able to look at the kx250f? By the pictures it looks more like the k5/T4 spline on the inner hub. I'm only going by images though. Wouldn't the basket be the easier to make work than the inner hub? What adds to the complication is that the my release and rod are on the pressure plate side. Don't use the rod like your k5. Really want to hammer something out. I'd like to do more reading about the back torque limiter. See if that's something I could look into. Seems like downshifting into turns and stuff my quads rear end will chatter

[Sandblaster]

Actually, I never even thought about the 250F stuff.
I'll take a look but I'm pretty sure the 250F stuff is smaller..
More later..

[dirk_411]

Well my basket is the same O.D. as the k5. I bet they will be very close. Eagerly awaiting.... out of the hinson parts I looked at the kx250f stuff looked the closest. I'm going to see if I can count splines from the pictures

[dirk_411]

I'm not sure what I was looking at now.....I went back and looked and it appears the 250f appears more like the 450f. My rant may have been for not