clutch and braking on the kx 500

[JAREDKRAUS]

Bought a 2002 Kx 250 with a Kx 500 motor. 
Sweet ride, however I still have the same problem as with my old 1992
Kx 500.  Need better braking and an easier clutch pull.  Do they make an
oversized front disc for the 2002 kx 250?  For the clutch, I've used an MSR Raptor
clutch lever for easier pulling.  Is there a better way? Hydraulic? Any advice would
be great.  Thanks

[sandblaster]

Brakes:
Galfer and EBC make oversized rotors with the brake relocation brackets from 270mm to 320mm.
I run a 320mm EBC on my K5.
This size is only practical for street or sand riding as rocks and logs will tear up an unprotected rotor.
You can also improve the brakes with a change in pads such as EBC's MXS pads.
They will wear you rotors out faster but they grip harder.
You can also use stainless steel brake hoses.

[JAREDKRAUS]

Thanks. I appreciate the advice.  Been riding a CRF 450 r and we all know they are
easier to ride and slowing down in the corners.  Due to high maintenance, the tractor power
is gondie.  With six bikes to maintain, 2 stroke is the only way to go. What are you using
for easier clutch pull? By the way, since I'm a newbie, is there an annual ride - athon? I'm in
Kansas and would love to meet some of the riders. 

[don46]

extend the clutch arm by about 10mm, that makes them easier to pull, also make sure you have a good cable, wore out and kinked pulls hard and lastly go to a CR lever and perch, they have a bit different ratio

[2-Stroke Tom]

First, get a brand new oem cable. Next, do the cable modification where you straighten the curved metal jacket on the cable to go around the outside of the frame. Here's a link to a picture of this modification on my bike - http://s1246.photobucket.com/albums/gg620/rjhansens/?action=view&current=IMG_0590.jpg

Then, put a real high quality clutch perch on. Team Green used Works Connection so my bike had that on when I got it. Since I wanted matching brake and clutch levers, I changed to ASV clutch and brake levers and these are awesome. Unbreakable, and they have a bearing for the clutch perch pivot which makes a big difference. My bike already came with these modifications, but a new oem cable and clutch perch made it as easy to pull as a 250.

[sandblaster]

Here is the thread on how to make your own billet clutch arm:
http://www.kxriders.com/forums/index.php/topic,10699.0.html

[alward25]

I have a 05 CRF 450 master cylinder with stainless brake line I am looking to part with.  All the nissin brake calipers on the jap bike are all about the same for the most part, the mount is different.  I changed a mount on a 07 yz 450 caliper and put it on my 2001 k5 and it was the same.  The master cylinder is key, the stock rotors suck too.

Alex

[JAREDKRAUS]

Thanks fellas.  My uncles have owned a machine shop for over 40 years.  They build
a lot of aircraft parts for the aircraft business here in Wichita, Kansas.  Also, a friend
of mine from high school owns a large machine shop and does the same thing.  I will take
your idea and have one of them make one.  Just give me a little time.  They should be able
to make an exact KX shaft with splines to match the yamaha clutch arm.