2 piece clutch cover

[sandblaster]

On goes the cut down clutch cover (Now a inner clutch cover)



On goes the outer clutch cover and adapter:

[sandblaster]

On goes the kick lever and the rear brake lever



Just barely...





While it does not rub, it is close, so I may slightly bent my brake lever out, then again probably not cause I'm lazy.
I also found some hidden dirt and grease on my bike.... I was shocked 

[Foxx4Beaver]

that looks good, pedal is a little close....I zip-tied a piece of inner tube to the back side of my brake pedal to help create a cushion/buffer.



it's nothing pretty, nothing fancy...but better than metal hitting metal if it takes a hit.

[Goat]

Where did the dirt and grease come from!? It's not like you ride it lol

That is a snug fit but looks factory. Nice work.

[sandblaster]

that looks good, pedal is a little close....I zip-tied a piece of inner tube to the back side of my brake pedal to help create a cushion/buffer.



it's nothing pretty, nothing fancy...but better than metal hitting metal if it takes a hit.

I like the idea of the cushion.
I originally had another 1/8" of clearance from the inside of the rear brake lever to the outside of the clutch cover.
The problem is, the thinner I make the adapter, the thinner the bolt tangs are.
If I go to thin the bolt tangs will strip easily so I'm trying to find a balance...
Might even add a spacer to the inside rear brake lever and push it out a bit  

[Foxx4Beaver]

knock on wood it hasn't really been "put to the test" yet, it has fallen over gracefully on it's side once, and it did just fine...but as you know, if it takes a hard enough hit, it won't matter what's behind it for a buffer.

I understand your dilemma about the adaptor and the tangs...but knowing you, you'll come up with a solution.

EDIT...I've actually been using a HEAVY gauge o-ring behind the brake lever as a spacer with decent results so far.

[motopunk]

On goes the kick lever and the rear brake lever



Just barely...





While it does not rub, it is close, so I may slightly bent my brake lever out, then again probably not cause I'm lazy.
I also found some hidden dirt and grease on my bike.... I was shocked 

gentlemen clap your hands for sandblaster. we have the first practicable solution. 
mike do you thought of cut down the inner cover a little bit more instead of the adapter ring, to eliminate the clearance problem to the brake?

here is a pic of billy liles 1990 / 91 kx500sr to comparing .

http://www.mxclassicracing.com/images/dsc0148_579.jpg
if you look good, it seems that the engine was the next step in evolution and they used the smaller bigger diameter basket of the 92-04 kx250 to get the engine smaller. the outer cover and waterpump looks also like later 250 parts like dutchy said in a former post.
 in the next time i will try the fitment of an 250 inner cover from my 96 kx360 big bore engine to the k5-engine. i am excited how close the covers would be in direct comparing.

[sandblaster]

Mr. Moto...
I have been scratching my head over this for some time.
I really hate to cut the adapter ring any thinner.
I could go a little thinner but not enough to make a practical difference.
Don't get me wrong, every little bit helps but I really want to keep all the strength in the adapter that I can.
Machining the inner clutch cover down is also not a good idea because I'm already as thin as I can go without cutting onto the governor area.
However... I came up with another solution this morning  
I will take another look this morning and see if it will work.. But I think it will.

[don46]

If you have clearance you could machine the cover mating surface down a bit, it looks like the tabs are pretty thick, or take the ring down and use steel inserts to prevent stripping. or make it easy on your self and bend the brake lever

[sandblaster]

Thanks Don.... You blew my big surprise 
Yes, that is exactly where I was going with it.
Of course, that adds one more machine process, and that adds money.
My original adapter was much more elaborate and would look really cool but it would be much more expensive so I have done everything I can think of to make it as cheap as possible yet still acceptable for aesthetics.
Again, trying to find the balance with cost conscious riders in mind.

[motopunk]

Thanks Don.... You blew my big surprise 
Yes, that is exactly where I was going with it.
Of course, that adds one more machine process, and that adds money.
My original adapter was much more elaborate and would look really cool but it would be much more expensive so I have done everything I can think of to make it as cheap as possible yet still acceptable for aesthetics.
Again, trying to find the balance with cost conscious riders in mind.

mr. sandblaster.. 
you do really great work with this project.. 
but this are all facts, that i not can see only from the pics.. only you are the man with the parts in hands. and only you could figure out, what will work best with it. i can only help a little bit with my logical thinking

and 100% agreed is : cheapest and easiest solution at this point is bending the brake lever ..   

[sandblaster]

cheapest and easiest solution at this point is bending the brake lever ..   

Maybe 

[don46]

the only thing about machining the cover, if you ever broke one you would have to machine it as well. If it was me I would take the most difficult route and bend the lever a little

[motopunk]

the only thing about machining the cover, if you ever broke one you would have to machine it as well. If it was me I would take the most difficult route and bend the lever a little

we could write a big book of pros and cons between mashining the cover or bending the lever.  the fact is to find the compromise between, to hold the costs on an acceptable level...   



quote author=sandblaster link=topic=11287.msg101659#msg101659 date=1393005940]

cheapest and easiest solution at this point is bending the brake lever ..   

Maybe 

that sounds like a little surprise that you plan to make ...   

[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 (Mistake).
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.