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Author Topic: 2 piece clutch cover  (Read 157382 times)

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Offline sandblaster

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Re: 2 piece clutch cover
« Reply #270 on: March 20, 2014, 05:14:51 AM »
You are so right Roost ... I did some research last night and you are spot on.
Then again I would expect nothing else from you  :-D
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline motopunk

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Re: 2 piece clutch cover
« Reply #271 on: March 20, 2014, 06:32:58 AM »
Quote from: sandblaster on March 20, 2014, 05:14:51 AM
You are so right Roost ... I did some research last night and you are spot on.
Then again I would expect nothing else from you  :-D

sympatic people, who sharing this knowledge are hard to find..  :-)...  the big trick is, that it looks after welding and  following processes like a non welded piece...  8-)
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big 2 stroke bikes are weapons for real men, who don´t fear death or devil. ;O)
´83 kx250, ´87 kx250 (with 360 big bore), 87 kx500, ´93 kx500 sfc

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Offline sandblaster

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Re: 2 piece clutch cover
« Reply #272 on: April 23, 2014, 07:57:45 AM »
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...

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2 piece clutch cover
« Reply #273 on: April 25, 2014, 10:34:51 AM »
After weld.



And does it fit?



Good!
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2 piece clutch cover
« Reply #274 on: May 19, 2014, 02:46:15 PM »
New bearings and seals... Install the inner clutch cover



Nothing binding...

Checking the clearance







Looks good with plenty of clearance  8-)
Looks like I might be able to take it for a test ride this week before I take it to the dunes.
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Offline Pmcg

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Re: 2 piece clutch cover
« Reply #275 on: May 20, 2014, 02:40:39 AM »
That came out great. Wouldn't know it wasn't factory.
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Offline sandblaster

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Re: 2 piece clutch cover
« Reply #276 on: May 20, 2014, 02:59:44 AM »
Just don't look too close  :lol:
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Offline Enginerd

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Re: 2 piece clutch cover
« Reply #277 on: May 20, 2014, 03:29:45 AM »
Quote from: sandblaster on May 20, 2014, 02:59:44 AM
Just don't look too close  :lol:
This really did come out great! Give yourself the credit you are due!  :mrgreen:
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Offline don46

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Re: 2 piece clutch cover
« Reply #278 on: May 20, 2014, 03:43:15 AM »
It really does look good, if you raise the brake pedal so it is level with the footpeg will it still clear? I couldn't get used to the brake pedal being that low. did you find somebody to build the adapter rings? if so that could be a very easy modification, buy the ring, cut the case, have the ring welded, and buy a 450 clutch cover, piece of cake.
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Offline sandblaster

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Re: 2 piece clutch cover
« Reply #279 on: May 20, 2014, 07:49:11 AM »
Clearance? Check!
What I did was adjust the rear brake set screw as far up as it would go, then I pushed up on the rear brake lever as far as it would go so you could see..





I think it fits as well if not better then the stock cover.
In fact, one my next one I will make the adapter ring about 1/16" thicker then I did this one.

When Roost slows down a bit and has a little extra time he is gonna water jet some rings for us.
You will have to cut your own cover, weld the ring, and tap some holes.
Roost is gonna water jet the tapped holes so all you need to do is tap them.
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Offline sandblaster

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Re: 2 piece clutch cover
« Reply #280 on: May 20, 2014, 07:58:39 AM »
Remember, I made this ring on my drill press with a carbide cutter free hand.
If you don't want to wait for Roost to make you one all you need to do is get a KX450F clutch cover.
Trace the perimeter on a piece of 1/4" aluminum.
Machine your KX500 clutch cover down so that it is about 1/4" below the surface of your water pump area (1.600" or so)
Then place the adapter over the hole in your KX500 clutch cover and trace the hole.
Cut is out with whatever, I used a jig saw.
Drill it and tap it.
Weld it.
Ride it.
Some of you guys could do it very quickly.
It took me forever just to figure out what I wanted because I have little to no idea of what I'm doing.
I need to ride it hard for a while to be sure there is no glitches but so far I am very happy with the results.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Goat

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Re: 2 piece clutch cover
« Reply #281 on: May 24, 2014, 06:05:28 AM »
d**n fine work SB. Just goes to show that you don't need the latest and greatest tools and equipment to do the job right.

I knew you could custom fab sandblaster :D It doesn't matter how long it takes as long as you're happy with it in the end.
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Quote from: Danger4u2 on June 17, 2010, 01:36:16 AM
It's hard to keep a drivers license riding a 2 stroke dirt bike on the street.  If you drive within the law they are VERY boring.

Offline sandblaster

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Re: 2 piece clutch cover
« Reply #282 on: May 24, 2014, 06:56:55 AM »
Thanks...
Now I'm debating if I want to make another by hand for my K5BC or wait for Roost.... :lol:
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2 piece clutch cover
« Reply #283 on: July 10, 2014, 03:25:42 PM »
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...



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



Then I could mix and match depending on my mood  :D
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2 piece clutch cover
« Reply #284 on: August 17, 2014, 11:01:45 AM »
I think I will run this one for a while...

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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