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Re: Making a KX500 2 piece clutch cover :-)
Posted: Thu Feb 20, 2014 11:24 pm
by Sandblaster
It was time to change the oil on my Sand machine so I decided to check my fitment..
- KX500 2 PIECE CLUTCH COVER ADAPTER 6.JPG (65.75 KiB) Viewed 26256 times
- KX500 2 PIECE CLUTCH COVER ADAPTER 7.JPG (64.04 KiB) Viewed 26256 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Thu Feb 20, 2014 11:25 pm
by Sandblaster
- KX500 2 PIECE CLUTCH COVER ADAPTER 8.JPG (72.14 KiB) Viewed 26256 times
- KX500 2 PIECE CLUTCH COVER ADAPTER 9.JPG (71.46 KiB) Viewed 26256 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Thu Feb 20, 2014 11:25 pm
by Sandblaster
- KX500 2 PIECE CLUTCH COVER ADAPTER 9-1.JPG (70.41 KiB) Viewed 26256 times
- KX500 2 PIECE CLUTCH COVER ADAPTER 9-2.JPG (65.48 KiB) Viewed 26256 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Thu Feb 20, 2014 11:26 pm
by Sandblaster
- KX500 2 PIECE CLUTCH COVER ADAPTER 9-3.JPG (56.46 KiB) Viewed 26256 times
- KX500 2 PIECE CLUTCH COVER ADAPTER 9-4.JPG (64.71 KiB) Viewed 26256 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Fri Feb 21, 2014 7:04 pm
by Sandblaster
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 26254 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Fri Mar 07, 2014 2:09 am
by Sandblaster
Re: Making a KX500 2 piece clutch cover :-)
Posted: Thu Mar 13, 2014 11:16 pm
by Sandblaster
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 26243 times
Here we are ready for weld.
- KX500 2 PIECE CLUTCH COVER ADAPTER AND JIG 2.JPG (33.81 KiB) Viewed 26243 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Tue Mar 18, 2014 11:49 pm
by Sandblaster
Finally got the clutch cover adapter off to the weld shop today....
I should have it back within a week or so...
Re: Making a KX500 2 piece clutch cover :-)
Posted: Wed Apr 23, 2014 7:47 pm
by Sandblaster
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 26229 times
Re: Making a KX500 2 piece clutch cover :-)
Posted: Fri Apr 25, 2014 10:32 pm
by Sandblaster
After weld.
- KX500 2 PIECE CLUTCH COVER ADAPTER AFTER WELD.JPG (59.08 KiB) Viewed 26228 times
And does it fit?
- KX500 2 PIECE CLUTCH COVER ADAPTER AFTER WELD 2.JPG (63.49 KiB) Viewed 26228 times
Good!