Maintenance & Technical > KX500 Original
A few tiny tricks I do to my bike.
1989kawasaki:
i would do that clutch cover bit.... but not on the last brand new clutch cover i could find for my kx250
kwakman:
i think seeing as the 250 from 85 to 90 and 500 from at least 85 to 04 uses the same lower cradle shape its about time we had some wardy esque case saving bars bent as per Motorrads bike.the only difficulty here is making sure they clear the pipe being used as the pipes differ substantially and if you can you may as well make sure it protects the water pump whilst your at it.this is where pipe clearance becomes critical.gona look into this a bit deeper,may need some pipe/water pump clearance measurements though.(Ironically, my millet wont allow use of these,but they're a good idea).K.
Polar-Bus:
Great mods and tips ! Even an old skool dirt bastard like me can learn something new and fresh ! Thanks for taking the time to share !
awak100:
Hey dude next time you put a clutch pack on your 5, take your clutch housing to your nearest welder and have him weld your break on the inside. Looks alot better then your patch. I just cut my clutch and brake levers off two fingers deep. They dont stick out so far then. Dont break them as often either
Polar-Bus:
--- Quote from: awak100 on May 13, 2012, 04:44:52 PM ---Hey dude next time you put a clutch pack on your 5, take your clutch housing to your nearest welder and have him weld your break on the inside. Looks alot better then your patch.
--- End quote ---
Too risky. What happens if your brake lever wears through the case, and the welds on the inside are not 100% sealed ? Tranny fluid will leak, and now you need to weld again. What about possible metal to metal interference from the internal spinning clutch hub ? Sorry to pee all over your idea, but the brake pedal buffer on the outside is far more functional.
--- Quote from: awak100 on May 13, 2012, 04:44:52 PM --- I just cut my clutch and brake levers off two fingers deep. They dont stick out so far then. Dont break them as often either
--- End quote ---
You must have gorilla finger strength, cause there is NO way I could ride a KX500 in the tight woods with a shory clutch lever ! Let alone stubby levers with the end balls sawed off. My final tip to minimise broken /bent levers is to leave the pinch bolts loose. Tighten the pinch bolts so it takes a good whack with your palm to get them the perch assembly to rotate. No more snapped levers, as the perch rotates upon a dirt impact.
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