KX500 2 piece clutch cover adapter

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Nice.
I used Smart Cam (Junk Cam)
I liked MasterCam way better...

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It's too late to turn back now

1st cut.JPG (73.09 KiB) Viewed 14676 times

My plan was to get a slot started with my saws all and then switch over to my jig saw.
But, after I got going it was cutting so nice and straight I just kept going.
It was the best saws all cut I have ever made
This is just so I can see better what I am working with.
This will have to be milled at some point but it plenty good for now...

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Due to the clearance of the water pump cover I think we are limited to about 6 13/16" in diameter.

water pump clearance.JPG (38.74 KiB) Viewed 14675 times

It's possible that we could offset the cover somewhat but I won't able to get my fingers in there to remove the bottom most clutch plates.
Then again.... we'll see on that.

BASKET DIAMETER.JPG (41.51 KiB) Viewed 14675 times

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This is a KX450F gasket laid over the KX500 clutch cover:

KX450F GASKET LAID OVER A KX500 COVER.JPG (66.94 KiB) Viewed 14674 times

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This is off a CRF450R 04 Honda.
It fits really close but by the time I trim the case down it will be too small..

CRF450R HONDA CLUTCH COVER ON A KX500 CLUTCH COVER.JPG (45.35 KiB) Viewed 14673 times

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I just ordered a test clutch cover for a 08 and newer KX450F.
As soon as it get's here we'll do some more head scratching with it.

KX450F CLUTCH COVER.JPG (20.16 KiB) Viewed 14668 times

With a oil fill hole in the inner and outer clutch cover I could fill it up twice as fast

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As soon as I get the cover in I will make a quick profile drawing of it in CAD and take it to a machine shop next door and see what they would charge to make up some profiled rings.
Of course it would be a lot easier just to use round stock OD and ID and machine a round cover for it.
But when have I ever took the easy way

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Here is a 2 piece clutch cover in the making from Cmotodad.

method1.jpg (77.42 KiB) Viewed 14661 times

method1-1.jpg (79.39 KiB) Viewed 14661 times

method1-2.jpg (85.95 KiB) Viewed 14661 times

He has a really nice start.
Can't wait to see it finished.
This is about the easiest way to make the 2 piece cover as it does not use a stock outer cover from another bike.
Trying to modify a stock cover from another bike to fit is proving to be difficult but certainly not impossible

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I received the KX450F clutch cover today and I think it's a go.
I'll need to get the CAD software dusted off and see what I can come up with..

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Here is a picture of the KX450F clutch cover sitting on top of the KX500 clutch cover.

KX450F CLUTCH COVER on a kx500 clutch cover.JPG (43.65 KiB) Viewed 14649 times

KX450F CLUTCH COVER on a kx500 clutch cover 2.JPG (36.83 KiB) Viewed 14649 times

KX450F CLUTCH COVER on a kx500 clutch cover 3.JPG (35.45 KiB) Viewed 14649 times

KX450F CLUTCH COVER on a kx500 clutch cover 4.JPG (49.22 KiB) Viewed 14649 times

KX450F CLUTCH COVER on a kx500 clutch cover 5.JPG (34.51 KiB) Viewed 14649 times