KX500 2 piece clutch cover adapter

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Since I have a 2 piece clutch cover..... and it uses a kx450f cover.... and I have a Hinson clutch basket.... I was thinking about this...

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In fact, I could get a Pro Circuit cover like this...

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Then I could mix and match depending on my mood

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I think I will run this one for a while...

kx500 kawasaki 2001 supermoto with hinson clutch basket cover.jpg (80.93 KiB) Viewed 22981 times

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Davi Millsaps KX450F clutch cover.

DAVI MILLSAPS KX450F CLUTCH COVER.png (368.74 KiB) Viewed 22968 times

I'd love to trade him

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I finally got a quote to make the adapter rings without the holes in them.
So, you would have to drill and tap your own holes.
Not a big deal but still a pain.
They would be water jetted from 1/4" 6061 Aluminum plate.
I'll talk to the guys at KXriders and see if anyone is interested...

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Just a few weeks more... hopefully.

You gotta admit, these look pretty sexy

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I spoke to Roost today and he beat me to posting his pic
Roost will be making 2 piece clutch covers complete.
You will need to send him your clutch cover.
The first batch was made from 3/16" not the 1/4" we wanted...
But I think they will still work.
As soon as I get my hands on my batch I will give it a good try and see what happens.
I'm ready, where's my adapters???

KX500 2 PIECE CLUTCH COVER.JPG (100.23 KiB) Viewed 22889 times

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Looking like about 3 more weeks

I have another victim ready to go to the machine shop..

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Now available for sale!
I only have a few that aren't spoken for so get em quick!
I'll have another batch soon.
This current batch are 3/16" thick and have the holes tapped.
The new batch will be 1/4" thick but will not have the holes tapped.

OEM-CYCLE.COM KX500 2 PIECE CLUTCH COVER ADAPTER RINGS 100.JPG (78.66 KiB) Viewed 22838 times

OEM-CYCLE.COM KX500 2 PIECE CLUTCH COVER ADAPTER RINGS 101.JPG (53.68 KiB) Viewed 22838 times

OEM-CYCLE.COM KX500 2 PIECE CLUTCH COVER ADAPTER RINGS 102.JPG (45.54 KiB) Viewed 22838 times

OEM-CYCLE.COM KX500 2 PIECE CLUTCH COVER ADAPTER RINGS 103.JPG (40.63 KiB) Viewed 22838 times

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RoostiusMaximus

Welding the two piece clutch cover adapter
I've been able to have a junk main case handy so I bolted the clutch case to it, do what you can to clamp it on something flat. If the cover has had a previous ding in it then it'll be twisted to start with.

Don't try to clamp the ring down to the work bench etc. The heat from the welding will distort the case. If you need to hold it to get it tacked on then do it with a c-clamp or something that won't follow the case like a visegrip etc or it'll keep compressing until the case cools down.

I bake the case on a hotplate until I can tap out the governor bearing, not so that the bearing turns blue. The case should sweat out what oil it has absorbed and be much cleaner welding.

Start near the governor area, its the thinnest so do it before it gets too hot to work with. move counter clockwise so you end up at the heaviest portion of the case last.

should go smooth.

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Here is some updates...
People ask me how thick should they cut their case to.
That will depend on what you are trying to do.
For a standard clutch assembly simply cut the case down until it is 1/4" lower then the water pump face as shown below.

www.oem-cycle.com kx500 two piece clutch cover 101.JPG (44.54 KiB) Viewed 22474 times

Now, if you want a Rekluse clutch there is two different ways of doing it.
I highly recommend that you get the parts together first then measure to be sure that the measurements will meet your needs.

1. If you use a KX450F clutch cover then you need to machine the clutch cover to the same thickness as the water pump cover face, NOT 1/4" lower.

2. If you use use a KXF450 (Quad) clutch cover, then you can machine the clutch cover 1/4" lower then the face of the water pump cover as shown in the pic above.

Again, measure first... then cut

Here's another tip.
While you have the clutch cover in the milling machine, remove the web as shown in the pic below.

www.oem-cycle.com kx500 two piece clutch cover 102.JPG (67.21 KiB) Viewed 22474 times