KX500 2 piece clutch cover adapter

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It was time to change the oil on my Sand machine so I decided to check my fitment..

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KX500 2 PIECE CLUTCH COVER ADAPTER 8.JPG (72.14 KiB) Viewed 26255 times

KX500 2 PIECE CLUTCH COVER ADAPTER 9.JPG (71.46 KiB) Viewed 26255 times

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KX500 2 PIECE CLUTCH COVER ADAPTER 9-1.JPG (70.41 KiB) Viewed 26255 times

KX500 2 PIECE CLUTCH COVER ADAPTER 9-2.JPG (65.48 KiB) Viewed 26255 times

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KX500 2 PIECE CLUTCH COVER ADAPTER 9-3.JPG (56.46 KiB) Viewed 26255 times

KX500 2 PIECE CLUTCH COVER ADAPTER 9-4.JPG (64.71 KiB) Viewed 26255 times

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Ok, this shows the new clearance.
This time I bolted the inner clutch cover down.
Yesterday, I had it sitting loosely on the engine.
I also took Foxx4Beaver's advice and put a small O-Ring behind the rear brake lever which helps push the lever further from the case.
Even if you push the brake lever as far as you can toward the engine, it still does not hit.
So, I am happy with the results and will have my adapter welded to the inner clutch cover.

KX500 2 PIECE CLUTCH COVER ADAPTER 9-6.JPG (47.53 KiB) Viewed 26253 times

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Made a little more progress today making a weld fixture to keep the adapter from warping during weld.

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Here is the adapter bolted to the jig as it is back from surface grind to make sure it's flat.

KX500 2 PIECE CLUTCH COVER ADAPTER AND JIG 1.JPG (36.16 KiB) Viewed 26242 times

Here we are ready for weld.

KX500 2 PIECE CLUTCH COVER ADAPTER AND JIG 2.JPG (33.81 KiB) Viewed 26242 times

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Finally got the clutch cover adapter off to the weld shop today....
I should have it back within a week or so...

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Since my shop was broke into I have been really set back in all my projects.
The bike that I was using to test fit the two piece clutch cover on was stolen so I had to come up with another test fit method.
This should do nicely.
Junk case, junk trans shaft, and a junk clutch basket...

kx500 2 piece clutch cover test fixture.JPG (40.89 KiB) Viewed 26228 times

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After weld.

KX500 2 PIECE CLUTCH COVER ADAPTER AFTER WELD.JPG (59.08 KiB) Viewed 26227 times

And does it fit?

KX500 2 PIECE CLUTCH COVER ADAPTER AFTER WELD 2.JPG (63.49 KiB) Viewed 26227 times

Good!