Maintenance & Technical > KX500 Original
2 piece clutch cover
USMC 500:
Well I don't want to put that kind of pressure on you.......thats why I've set the deadline to mid next week. :-D
sandblaster:
As a double check, I need to know what the measurement from the outside of the right engine case to the furthest point away from the clutch asy is.
Just checking if the new cover will have the correct clearance.
I believe that it will but I don't have an engine that I can check this with right now.
Right now I have a total thickness of 1/2" for the adapter.
Unfortunately that would make the outside of the KX450F clutch cover stick out approximately 1/2" past where the stock clutch cover ends...
I can easily make the adapter thinner.
However, I am concerned about thread engagement with the aluminum.
Take a look at the pics below.
Right now I am set up for a full 1/2" of thread engagement.
In reality I know this is overkill as there won't be any real stress on it.
However, there is always the guy who over-tightens everything....
So in your opinions, what would be the safe amount of thread engagement?
After all, the thinner the adapter, the closer to the original cover position we can get which means less tweaking of the rear brake lever...
USMC 500:
don't worry about those who "overtighten"......just send us some torque specs and make that sucker as close to the stock dimensions as possible.......thats my desire anyways. :wink:
sandblaster:
The other concern I have is what the face will do after it's been welded.
What some of you may or may not know is the K5 clutch cover in the basket area is not perfectly round.
Therefore, some of the areas will require a bit more weld material (Gap rod) then others.
So, I'm worried about warpage after weld.
If I leave a little more material then the face can be machined to clean up after weld.
And for those that are really fussy (They know who they are) they can lap it as well :-D
Any suggestions?
Motorrad:
--- Quote from: sandblaster on March 06, 2013, 04:57:24 PM ---The other concern I have is what the face will do after it's been welded.
What some of you may or may not know is the K5 clutch cover in the basket area is not perfectly round.
Therefore, some of the areas will require a bit more weld material (Gap rod) then others.
So, I'm worried about warpage after weld.
If I leave a little more material then the face can be machined to clean up after weld.
And for those that are really fussy (They know who they are) they can lap it as well :-D
Any suggestions?
--- End quote ---
Get a smart welder. Tack opposite corners. and only weld small sections at a time. to not build up heat. and use a heat synk (sink?) im bad speller
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