KX500 2 piece clutch cover adapter

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Sandblaster
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Re: Making a KX500 2 piece clutch cover :-)

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kx500 2 piece clutch cover 9-5.png
kx500 2 piece clutch cover 9-5.png (313.84 KiB) Viewed 25201 times
kx500 2 piece clutch cover 9-1.png
kx500 2 piece clutch cover 9-1.png (1004.05 KiB) Viewed 25201 times
kx500 2 piece clutch cover 9-2.png
kx500 2 piece clutch cover 9-2.png (330.33 KiB) Viewed 25201 times
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Re: Making a KX500 2 piece clutch cover :-)

Post by Sandblaster »

Ok, enough monkey business.
The following pics are of a 89 kx250 clutch cover sitting on top of my cut down kx500 inner clutch cover.
As you can see, you can make an adapter for it but then you are stuck buying a used clutch cover any time you break yours... :x
89 kx250 clutch cover on a kx500 inner clutch cover 1.jpg
89 kx250 clutch cover on a kx500 inner clutch cover 1.jpg (282.07 KiB) Viewed 25194 times
89 kx250 clutch cover on a kx500 inner clutch cover 2.jpg
89 kx250 clutch cover on a kx500 inner clutch cover 2.jpg (246.44 KiB) Viewed 25194 times
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Re: Making a KX500 2 piece clutch cover :-)

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89 kx250 clutch cover on a kx500 inner clutch cover 3.jpg
89 kx250 clutch cover on a kx500 inner clutch cover 3.jpg (265.68 KiB) Viewed 25194 times
89 kx250 clutch cover on a kx500 inner clutch cover 4.jpg
89 kx250 clutch cover on a kx500 inner clutch cover 4.jpg (255.4 KiB) Viewed 25194 times
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Re: Making a KX500 2 piece clutch cover :-)

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89 kx250 clutch cover on a kx500 inner clutch cover 5.jpg
89 kx250 clutch cover on a kx500 inner clutch cover 5.jpg (255.91 KiB) Viewed 25194 times
Looking close at the pics, you can see that the 89 kx250 clutch cover is slightly smaller then the KX500 inner clutch cover.
Making a adapter for it is doable as stated above but it somewhat negates a big reason for doing a adapter and using a newer kx450f clutch cover.
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Re: Making a KX500 2 piece clutch cover :-)

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About 2 days before Roost volunteered to machine some of the adapters I had started making a adapter by hand.
Since I don't have a mill I used the next best thing.
Poor mans milling machine....
poor mans milling machine 2.jpg
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Re: Making a KX500 2 piece clutch cover :-)

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Done with the poor mans water jet and milling machine.
KX500 2 PIECE CLUTCH COVER ADAPTER 1.JPG
KX500 2 PIECE CLUTCH COVER ADAPTER 1.JPG (37.22 KiB) Viewed 25190 times
KX500 2 PIECE CLUTCH COVER ADAPTER 2.JPG
KX500 2 PIECE CLUTCH COVER ADAPTER 2.JPG (36.31 KiB) Viewed 25190 times
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Re: Making a KX500 2 piece clutch cover :-)

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Poor mans milling machine in action

http://www.youtube.com/watch?v=Qp2qYJk_ ... e=youtu.be
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Re: Making a KX500 2 piece clutch cover :-)

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There is a lot of chatter and it has a tendency to jump out of your grip,
This only happened once and I didn't like it :-(

http://www.youtube.com/watch?v=X-gkWTEL ... e=youtu.be

If your gonna try it, just be careful 8-)

This is still rough but it is taking shape.
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Re: Making a KX500 2 piece clutch cover :-)

Post by Sandblaster »

Now I'm waiting for my KX450f clutch cover to come in so I can confirm the geometry and then get it polished, drilled, tapped, and welded on.
KX500 2 PIECE CLUTCH COVER ADAPTER 3.JPG
KX500 2 PIECE CLUTCH COVER ADAPTER 3.JPG (61.49 KiB) Viewed 25182 times
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Re: Making a KX500 2 piece clutch cover :-)

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More progress
KX500 2 PIECE CLUTCH COVER ADAPTER 4.JPG
KX500 2 PIECE CLUTCH COVER ADAPTER 4.JPG (107.76 KiB) Viewed 25177 times
KX500 2 PIECE CLUTCH COVER ADAPTER 5.JPG
KX500 2 PIECE CLUTCH COVER ADAPTER 5.JPG (104.88 KiB) Viewed 25177 times
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