Maintenance & Technical > KX500 Original
2 piece clutch cover
cmotodad:
When I sat the cover on the bench, it measured 3.25" from the bench to top of stock cover. That is the reason I am making a one-off cover, to get thread engagement and keep stock width. They say if you are using 6mm bolt, then 6mm of engagement is all you need. Seems kinda short to me.
sandblaster:
--- Quote from: cmotodad on March 06, 2013, 06:22:10 PM ---When I sat the cover on the bench, it measured 3.25" from the bench to top of stock cover. That is the reason I am making a one-off cover, to get thread engagement and keep stock width. They say if you are using 6mm bolt, then 6mm of engagement is all you need. Seems kinda short to me.
--- End quote ---
Thanks.
If I was making my own cover like yours the adapter plate would have to be a lot thicker and I would have plenty of room for thread engagement.
But a factory KX450F cover is already thick on it's own.
So I have to keep the adapter plate thin so that the cover does not stick way out.
I'll take my clutch cover off my only assembled K5 and take some pics with my cut up cover.
With steel I agree that 6mm would be plenty of thread engagement.
With aluminum I have always use 2 times the diameter.
Might be overkill but it always worked :-D
This cover won't really take a lot of abuse so I'm going to risk it... :-o
cmotodad:
Are you going to go with 6mm engagement or closer to 10mm? I think the extra 4mm would be cheap insurance for threads. Did you have a problem with the ring near the w/p area of cover? That is where mine got a little tight.
sandblaster:
--- Quote from: cmotodad on March 07, 2013, 02:58:30 AM ---Are you going to go with 6mm engagement or closer to 10mm? I think the extra 4mm would be cheap insurance for threads. Did you have a problem with the ring near the w/p area of cover? That is where mine got a little tight.
--- End quote ---
I'll know better on the engagement once I get my clutch cover off and install my trimmed up cover.
Yes the water pump area is the problem area.
I'll probably index my adapter there to not only fit better, but also for alignment at installation.
It would not be funny to weld on your cool new adapter only to discover you put it on upside down :-o
I'll try to find some time to get some pics of it today..
don46:
One of the issues you will have, is the brake pedal, on the side closest to the brake it will need to be angled pretty good to prevent dragging. There was a picture on here someplace of the 2 piece cover I made, and if you can find it you'll notice that it is angled to clear the brake lever, mine was never in a stock 500 chassis, but you all know the brake is close and tends to damage the case if dropped on that side. when I built mine the first time I made it flat, similar to doordie's cover, it would'nt work because the brake hit it, so then I went back to the drawing board.
To be honest that cover is on a spare engine, clutchs rarely go on my 500 so really it is the bling factor more than anything.
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