Clutch Cover Mod

[2-Stroke Tom]

When I bought my KX500 from Team Green, I was disappointed that my bike did not have the clutch cover mod. I raced desert for years on KX80s, KX125s, and KX250s and never replaced a clutch on any of my bikes (probably because I was using the recommended 10w-30 oil!). This is my first 500, so I wasn't sure if it would be different from my other bikes. Well, I bought the bike used and have put about 30 gallons of fuel through it, and it hasn't missed a beat.

One thing that I have noticed though is that my oil gets dirty almost instantly. I change it every ride, and it's always dark. None of my other bikes ever did this, but they were mostly stock. I think this bike has a Hinson basket and steel clutches, but does anyone else have this issue?

I put a photo of my bike that I took last weekend at El Mirage Dry Lake. She is now ready to desert race!

[Motorrad]

When I bought my KX500 from Team Green, I was disappointed that my bike did not have the clutch cover mod. I raced desert for years on KX80s, KX125s, and KX250s and never replaced a clutch on any of my bikes (probably because I was using the recommended 10w-30 oil!). This is my first 500, so I wasn't sure if it would be different from my other bikes. Well, I bought the bike used and have put about 30 gallons of fuel through it, and it hasn't missed a beat.

One thing that I have noticed though is that my oil gets dirty almost instantly. I change it every ride, and it's always dark. None of my other bikes ever did this, but they were mostly stock. I think this bike has a Hinson basket and steel clutches, but does anyone else have this issue?

I put a photo of my bike that I took last weekend at El Mirage Dry Lake. She is now ready to desert race!

Only time I had that issue was when running alum clutch plates...
swap to steel.. and problem goes away...

where do you desert race?  I race D38...   I asume your D37?

[2-Stroke Tom]

I raced D37 for years, but I took a break from racing when I went away to college and to get my career going. When I saw a real Team Green KX500 for sale, it was just the inspiration I needed to get back into it. I haven't raced the bike yet, but I'm trying to put some hours on her to get used to it. I can't wait to do my first bomb run on the KX500!! Now if I eat dust on the bomb, it will be due to my lack of courage to hold the bike wide open for a prolonged period, not because my bike is topped out at 85mph like my old 250.

The KX500 was dominating the desert when I got out of racing and continued to do so until 2005 (they raced the 2004 KX500 in 2005 since the 450 wasn't ready to race yet). Instead of buying a new KX450, I thought I would reintroduce myself to desert racing on the most tried and true desert machine ever. Not to mention, nothing like going riding with all of your buddies who refer to your bike as "A man's bike". It's the only bike I've owned that people are afraid to take for a spin!

[Motorrad]

I raced D37 for years, but I took a break from racing when I went away to college and to get my career going. When I saw a real Team Green KX500 for sale, it was just the inspiration I needed to get back into it. I haven't raced the bike yet, but I'm trying to put some hours on her to get used to it. I can't wait to do my first bomb run on the KX500!! Now if I eat dust on the bomb, it will be due to my lack of courage to hold the bike wide open for a prolonged period, not because my bike is topped out at 85mph like my old 250.

The KX500 was dominating the desert when I got out of racing and continued to do so until 2005 (they raced the 2004 KX500 in 2005 since the 450 wasn't ready to race yet). Instead of buying a new KX450, I thought I would reintroduce myself to desert racing on the most tried and true desert machine ever. Not to mention, nothing like going riding with all of your buddies who refer to your bike as "A man's bike". It's the only bike I've owned that people are afraid to take for a spin!

Well. when my motor is back together. (within the next month).... we will have to get together and run a D38 or D37 race... As my bike is a EX-Team green bike also...    Can be a Ex-team green party or somthing...    Make sure destry is there.. so I can pass him in a straight away to remind him what he is missing out on now...

[2-Stroke Tom]

We should team up and do a race Motorrad, that would be a lot of fun. I've been watching your posts on your Ex-Team Green bike, and you've got a really nice machine that I'm sure all of your hard work and attention to detail will pay off. I haven't done anything to my motor yet except for doing a leakdown test when I first got it, and based on the test there didn't appear to be any problems. I like gathering data and seeing other builds to get ideas for when I do rebuild the bike.

And I'm sure there are times when Destry misses the mighty KX500 power, as I've seen posts where  he discusses how the KX500 has the advantage on the KXF450 on 70mph and above. I'm sure the reason for the 70mph and above figure has a lot to do with traction, but I used to watch bomb runs where the KX500s in the hands of the pros would put a woopin' on all of the other bikes, and I never saw any of the pros have problems starting the bike at the drop of the flag like I've seen with the 4-strokes.

[PowerFiend]

I think most people would pass on it when they see the cost of it. What would you pay for one.

I paid something like $300 for a 2 piece cover for my 2005 KTM RFS when SFB was making them from billet, so something in the $300-375 wouldn't be unreasonable. Perhaps a billet inner cover to use an off the shelf KX250 etc. removable clutch cover to reduce costs?

Maybe just a machined stock one with a laser welded billet adaptor plate to  mount a stock KX250 cover???

[byron909]

i am still wanting to do this to my 86, i have found a few various year older kx250 side cover/ outer covers that i'll have soon. i wonder if those team green bikes had modified oem covers or totally new made ones from japan?
i envy you desert racer guys. i always wanted to do that, but where i live it just isn't so.

motorad i want an easy access cover just because for whatever reason i have a problem with kawasakis and clutch dragging. i have owned many kxs over my life, but have always had something needed on the clutch stuff. my last kawi build was a 86 500, everything clutch oriented is brand new, and still here i am with a small issue of it dragging.
maybe i am just lazy and don't feel like doing everything needed to remove it currently. if i had this outer cover it would be a few minute ordeal to sort out. wouldn't need to even drain any fluid, just lay on side.

[alward25]

I was going to make one using a kx450 outer cover.  Very common gasket and you can get some cool covers.  I am also going to make some outer covers too that could be personalized.  After my move in about 2 months.  I will keep you posted.
Alex

[1989kawasaki]

they should have put the removable outer clutch cover on the kx500 like they did to the kx250 in 88