KX500 2 piece clutch cover adapter

[Sandblaster]

Making a KX500 2 piece clutch cover

It's about time I get this project started

[Sandblaster]

So, here's the problem.
Most all dirt bike engines started using a 2 piece clutch cover in the late 80's.
Why?
Because one little rock nick and you have to either repair or replace your single piece clutch cover.
Can you say E.X.P.E.N.S.I.V.E ?
With a two piece clutch cover you toss the damaged outer clutch cover and install your cool new after market clutch cover.
Here is my busted cover.



The plan is to machine the broken part out, weld in some tabs, machine a new cover, and go ride it

[Sandblaster]

Yes, this can be repaired but where is the bling in that?
Stay tuned for more

[Motorrad]

alot of the reason was for easy clutch plate swaps.. (the race fellas.... are rough on clutch's)... especially in the lower CC bikes.



Im game... sounds like fun.. been wanting to do one myself.


Ive always thought destrys was the best looking... use Polished stainless hardware for the screws.. it would be a sharp looking piece..

[Motorrad]

If I was going to make one. I would go about doing it in such a way...


make the spacer piece (you can see it above in destrys bike).. only drill the holes in it for tap size (IE you run the tap through the holes AFTER its all finished and enlarge the other holes) (AND if you were a smart fella. you would make.../ KEEP a template to make more.. as many people would be willing to throw money at you to make one for them.. and this is the hardest part of the entire deal......

Personaly with MY tooling.. Id use a "keyway cutter" on the mill. mount the case gasket side down...


Now... when you made the "spacer piece" you factor in the thickness of the keyway cutter..




okay..


now you put the case in the mill. use the keyway cutter to cut off the face of the clutch cover..


take it all out of the mill


weld it all together (the case, your spacer, and your faceplate of choice (one you make or??) (FROM THE INSIDE).

Clean your welds if your a sloppy welder..


chuck it back in the mill.. make a final cut of the (removeable part)..


Tap the holes in the back half and enlarge the holes in the front (removable part) counter sink them... whatever you decide to do...




this method makes the most sense to me... (in my head... while sitting at the computer. we all know how projects like this work... things may change when your not sitting at the computer...

[Sandblaster]

I like that style the best as well.
What do you suppose we could use for the cover?

[Motorrad]

oh.. and if I had tons of junk piles laying around... Id be tempted to look at the main "big part" clutch cover off some of the early Kx250's to see if the diameter was correct.. and you could just take a slice out of one (like slicing a loaf of bread) for the "spacer)


could use the piece you cut off the stock (kx500) cover the way I described... as long as your not starting with a busted one....



Now.. If you ride in alot of rocks.. like you said above.. and want a "cheap" replacement one IF you do hurt one...

we need to think of somthign differant than what I described above.... and fine somthign that fits. (like slicing the kx250 ones like a loaf of bread)

[Motorrad]

You could also use a stock cover and Build up weld on the thing in marked out areas.. clean it up.. and take one slice....



there are MANY ways to go about this.. all depends on which kind of labor you prefer...

[Sandblaster]

I've got some covers ready to be pulled from storage as well as some inner clutch covers for measurements.
I like the sliced bread approach.
If it's close in profile that would be a real plus...
I checked out the 450f inner clutch covers but there is not enough material for the sliced bread method

[Motorrad]

I've got some covers ready to be pulled from storage as well as some inner clutch covers for measurements.
I like the sliced bread approach.
If it's close in profile that would be a real plus...
I checked out the 450f inner clutch covers but there is not enough material for the sliced bread method

shame.. I like the way the 2013 covers look..