KX Riders
Maintenance & Technical => KX500 Original => Topic started by: 1989kawasaki on February 24, 2013, 08:58:14 AM
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found this
http://forums.mxtrax.co.uk/showthread.php/337945-kawasaki-factory-kx500-two-piece-clutch-cover-sr500
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I'd like to have it for the cover.
200L = about 305 USD.
Too rich for my blood.
I didn't want to say anything earlier but I am going to start making one this week as time allows.
If anyone else wants to be involved I'm game.
I have seen all the styles available and am undecided which style I want to make.
But, I can get started machining the cover off...
Then we'll see what happens.
I may model some different covers in CAD just for grins...
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I'd like to have it for the cover.
200L = about 305 USD.
Too rich for my blood.
I didn't want to say anything earlier but I am going to start making one this week as time allows.
If anyone else wants to be involved I'm game.
I have seen all the styles available and am undecided which style I want to make.
But, I can get started machining the cover off...
Then we'll see what happens.
I may model some different covers in CAD just for grins...
sounds exciting!! :-D
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I don't know... Boring and exciting.
I'm hoping to find a stock cover from another bike that may simplify the project.
A cool bling cover would be nice as well..
We'll see.
I know others have been down this road before but I can't seem to find the correct thread.
I actually combined all the pics onto one thread but it's beyond me where.
Yes Motorrad, I used the search button :-)
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I am in the middle of my one-off 2 piece right now. I had a bad stock cover, machined the face off, made a ring to fit the outside, welded it on and am in the process of milling the outer cover now. The problem I found with avaliable covers was the depth would was too deep and still have room for the ringump area. Let me know how it goes. I will try to post pics when it is complete. Maybe with enough K5 owners interested, we could pool in and try for a sandcast 2 piece from the one for sale? I have a friend in the casting industry, I will talk with him soon.
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Assuming your making the cover from aluminum?
Or, maybe your doing the see through version?
Any pics of what you have done would be cool :-D
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Or.. I can buy the neeto magnesium one. and run it on my bike.. and be cool... :-D
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Oh, it would be cool... It's rotten around the water pump area....
That wouldn't be good for the flying M :-(
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Oh, it would be cool... It's rotten around the water pump area....
That wouldn't be good for the flying M :-(
Its.. Magnesium. just use the welding Tecnique DESIGNED TO WELD MAGNESIUM. its called TIG. Yes.. it was designed to weld mag. not alum like people think..
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Well, get that puppy....
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Well, get that puppy....
Im poor...
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Well, I talked with my contact in the casting industry. With the final cost of over 1k per piece and the setup fees of
$ 3500, I quess it is not feasible to try to make a 2 piece from the item for sale. Looks like the guy with the most money and a tig welder can have his very own cover to make the others jealous.
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Well, I talked with my contact in the casting industry. With the final cost of over 1k per piece and the setup fees of
$ 3500, I quess it is not feasible to try to make a 2 piece from the item for sale. Looks like the guy with the most money and a tig welder can have his very own cover to make the others jealous.
I have one of those things. :cry:
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If anyone would like to make a CAD drawing of one using a KX 250 or 450 cover so there is a common gasket, I could get one milled very cheap.
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If someone has access to a CMM it would certainly speed up the process of making the model :-)
Doing it by hand would take quite an investment in time :-(
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You are right. I have spent many hours working on this cover. I am doing it with a small mill I have in the garage. If I were to do it again, I would weld some round stock on the milled case a to match an existing cover. Right now I have a big pile of alu.shavings and a sore back.
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I didn't want to say anything earlier, but I am going to start making one this week as time allows.
Way to go Mike! I hope you can get it done! I'd love to have one!
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How's this comin along?
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Other then drooling I haven't even made it to the shop yet.
I probably won't get started today as Monday's are incredibly busy...
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If someone has access to a CMM it would certainly speed up the process of making the model :-)
Doing it by hand would take quite an investment in time :-(
And I do........
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My CAD program is getting a bit long in tooth but I can take the following formats:
IGES
STEP
ACIS .sat
Parasolid .x_t
STL
You might want to send me a test file so I can see if I can get it converted into something that I can work on.
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Anyone who abuses a kx500 clutch enough to require frequent clutch plate swaps and warrant the need for a 2pc cover has got my vote as god...
L
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Anyone who abuses a kx500 clutch enough to require frequent clutch plate swaps and warrant the need for a 2pc cover has got my vote as god...
L
I only want one for the Team green BLING factor..
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Too late to back out now...
(http://www.oem-cycle.com/forum/download/file.php?id=394)
By the way, that was the best saws all cut I have ever made 8-)
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I give you guys credit. Bling like that IS cool! When ever I have done a project that involved, usually someone says "All you have to do is put a flange on it." My mouth usually opens to give them a run down on all the work involved, then I re-think it and just smile and say "Yeah." They probably have never done something like that or just do not have a clue. Either way, not worth my time to educate them. Looks like a good start. You have a ruined cover! Now you HAVE to do it!
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Yeah, that cover had a bad dent in it that needed a repair any way so why not go for it?
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wow is that a perfect cut?
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Nope, but really close :-)
It will be machined down but I just wanted to get a better look at what I was dealing with and I'm impatient...
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I will take a pic of mine. It looks the same except for 6 tabs on a flange around the outside.
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Excellent!
Any pics of the two piece covers I'm interested in.
I used to be able to pull up several from this site.
At one point I took every pic from this site and combined them into one post.
I think after the recent trouble I think all those pics went bye bye :-(
So yes, POST YOUR PICS so I can steal them all :-D
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Here are few photos of the two piece cover that I'm working on:
(http://i82.photobucket.com/albums/j267/blacken145/kx4_zpsa8473ca9.jpg)
(http://i82.photobucket.com/albums/j267/blacken145/kx3_zpsa8313510.jpg)
(http://i82.photobucket.com/albums/j267/blacken145/kx1_zpscce02401.jpg)
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Looking good.
What cover do you have for that, stock off something or custom?
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Making a custom cover. It will not be flat. I am trying to make it similar to a production cover only not as deep.
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Nice.
Are you keeping the overall depth of the cover the same as stock or are you extending it out at all?
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Don't make it stick out too far , or else the brake pedal will rub on it
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I think I will machine some off the flange addition to keep the cover as close as possible to a stock width. This is going on the CRF/500 AF I am doing and the brake pedal is close to the cover stock.
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If you guys figure this out I'll take one for the "team green" nostalgia factor. :-D
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I received the KX450F clutch cover today and I think it's a go.
I'll need to get the CAD software dusted off and see what I can come up with..
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BLASTER, BLASTER, HE'S OUR MAN, IF HE CAN'T DO IT................awe crap :|..........hahahaha
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I received the KX450F clutch cover today and I think it's a go.
I'll need to get the CAD software dusted off and see what I can come up with..
I told you I liked that one........ For a reason. ;)
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You are evil.... :evil:
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You are evil.... :evil:
Ive been called worse.
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I know :-D
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What do you guys think about the alignment holes?
Keep them or loose them?
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Depends on if your making bread, or just slicing bread
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ditch them, i thought you wanted the inner cover, i have a spare outer like that one.
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the 89 kx250 clutch cover looks nice and round. but too bad its discontinued :(
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Depends on if your making bread, or just slicing bread
For right now I'm making bread.
If I make the bread I think I would keep the profile but skip making the holes as you would not have the alignment pins anyway.
If I decide to slice the bread at some point in the future the holes and pins would already be there.
But I'm always open to suggestions when it comes to baking..
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ditch them, i thought you wanted the inner cover, i have a spare outer like that one.
I looked at using an inner cover from the 450 and just playing sliced bread with it to make it fit to the KX500 clutch cover.
But, the more I looked at it the more I think that making a simple adapter would be the best way top go.
At this point my goal is to make adapter rings that others could take to a local fab shop and say, cut the outside of this cover off to "X" height from the base, weld this on to finish at "X" height, make sure it doesn't leak, bolt the cover of choice on it (As long as it is from a 06 or newer KX450F) and go ride.
I think in the future I may try the sliced bread method but for now I want the easiest solution.
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my boyeson cover i bought for my klx 450 had me remove the alignment pins. It seals fine without them.
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my boyeson cover i bought for my klx 450 had me remove the alignment pins. It seals fine without them.
Good to know.
Thanks!
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In fact, what I'm thinking about would look a lot like these:
(http://www.oem-cycle.com/forum/download/file.php?id=427)
(http://www.oem-cycle.com/forum/download/file.php?id=428)
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perfect!!!!!
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In the pictures it is at 1" thick.
It will be about 3/8" thinner then shown in an effort to keep the cover as close to the stock width as possible.
I have the preliminary blue prints at a machine shop to give me a quote on a production run of 10.
So at least we will have a rough idea...
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In the above pics the adapter is about 3/8" too thick.
Here is a better idea of how it will look.
(http://www.oem-cycle.com/forum/download/file.php?id=429)
(http://www.oem-cycle.com/forum/download/file.php?id=430)
I might be able to shave another 1/8" off the outer section but I need to do some checking first.
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In the pictures it is at 1" thick.
It will be about 3/8" thinner then shown in an effort to keep the cover as close to the stock width as possible.
I have the preliminary blue prints at a machine shop to give me a quote on a production run of 10.
So at least we will have a rough idea...
only 10.... I call dibs...
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I got dibs on one of the 10!! Whats a "Flying M" motor without some Team Green Bling Bling!!
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After I get one made and verify how awesome it is (or isn't) we can put together a list of how many we need and go from there.
I just had to give the shop a number to get started with.
If we need more, we'll get more.
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After I get one made and verify how awesome it is (or isn't) we can put together a list of how many we need and go from there.
I just had to give the shop a number to get started with.
If we need more, we'll get more.
I want mine by next week.......is that gonna be a problem sandblaster? :-D
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Next week?
I thought you guys were in a hurry? :-o
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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
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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.
(http://www.oem-cycle.com/forum/download/file.php?id=431)
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...
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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:
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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?
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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?
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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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.
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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.
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
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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.
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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.
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..
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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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Your right.
The brake lever is a concern which is why I have a few things up my sleeve :lol:
And, if my current method crashes and burns I have a back up plan :mrgreen:
If that does not work then I'll be forced to make a cover and adapter.
But, lets see how this one pans out first...
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After I did some closer measurements, the outer most edge of the cover is closer to 3" from the centercase.
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Yep.
That's closer to what I have.
I am pulling my unmolested cover off my sand bike today (If I have time) and get some good measurements for internal clearance.
I know there isn't a lot of wiggle room there either but in this case every little bit will count..
Machine it till it barely scrapes without a gasket, then, install a gasket.
Now where have I heard that line from :-D
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Here is a pic with the cutaway clutch cover that is being adapted.
(http://www.oem-cycle.com/forum/download/file.php?id=435)
Measuring to be sure we have the correct clearance.
(http://www.oem-cycle.com/forum/download/file.php?id=436)
Looks like I am right there 8-)
(http://www.oem-cycle.com/forum/download/file.php?id=437)
At this point I don't think I have to modify the rear brake lever at all :mrgreen:
I will get the clutch cover milled down in the next few days and then I will know for sure but for right now I think I am there without indexing the adapter which will save on machine time...
And.... I have about 9.5mm of thread engagement with a 6mm bolt.
I feel real good about that..
But, we'll see.
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Well, I finished up my cover and case. Pretty happy with the results. I will not have to worry about the cover being cracked like the old one, plenty thick. I will send pics when the son gets home.
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I know there isn't a lot of wiggle room there either but in this case every little bit will count..
Machine it till it barely scrapes without a gasket, then, install a gasket.
Now where have I heard that line from :-D
Oh No.....the Motorraditis is spreading!!!
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Chuck Norris doesn't need a clutch because he squeezes the steels and fibers with his bare hand.... :-D
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I can't wait to see how yours turns out..
I can't wait to see how mine comes out..
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I can't wait to see how yours turns out..
I can't wait to see how mine comes out..
if you show me yours... Ill show you mine :-o
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Here are the photos of the completed cover:
(http://i82.photobucket.com/albums/j267/blacken145/cover2_zps88c6c9b4.jpg)
(http://i82.photobucket.com/albums/j267/blacken145/cover1_zpsce50e207.jpg)
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d**n, that looks cool!! :-o
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Very nice.
I won't ask how many hours you have in it or how sore your back is :-D
Here is mine sitting in the CNC:
(http://www.oem-cycle.com/forum/download/file.php?id=444)
Here's a pic with the clutch cover cut to size.
(http://www.oem-cycle.com/forum/download/file.php?id=438)
We cut a bit into the W/P area and just touched the governor area but still it's all good.
Mounted on the bike
(http://www.oem-cycle.com/forum/download/file.php?id=439)
Outer cover on but no adapter installed.
It should stick out approximately .150 further then shown once the adapter is on and the gaskets are installed.
(http://www.oem-cycle.com/forum/download/file.php?id=440)
(http://www.oem-cycle.com/forum/download/file.php?id=441)
But is there enough room for the rear brake lever without modifications?
(http://www.oem-cycle.com/forum/download/file.php?id=442)
(http://www.oem-cycle.com/forum/download/file.php?id=443)
Yup.
Plenty of room 8-)
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Wish mine looked that stock. Maybe when they are ready, I may have to sign up for one. Confused as to which filler you will use for gearbox oil or is that like a CRF450? haha.Looks GREAT.
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You use them both and take half as much time filling your oil :-D
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You use them both and take half as much time filling your oil :-D
Or put a oil temp gauge in one. :wink:
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That's a good idea.
I'm already considering phase 2 which would be to have an adapter and a custom machined outer cover....
It could have some cool logo........
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That's a good idea.
I'm already considering phase 2 which would be to have an adapter and a custom machined outer cover....
It could have some cool logo........
I'd pay to have a ˭M˭ Kawasaki on one
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You use them both and take half as much time filling your oil :-D
Or put a oil temp gauge in one. :wink:
Or. mount it upside down. and have a quick access drain plug. (that doesnt have stripped otu holes like 95% of the K5's in the world)
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You use them both and take half as much time filling your oil :-D
Or put a oil temp gauge in one. :wink:
Or. mount it upside down. and have a quick access drain plug. (that doesnt have stripped otu holes like 95% of the K5's in the world)
Mine is one of the 5% that isn't stripped out. :-D
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Looking at these, and how cool they are, I was thinking, "Why not weld five or six half round pieces to my original cover, drill them undersize, then cut it off with a thin tool, tap the bottom, drill the top to size and put a gasket or RTV it back together?” Then I realize, MORE WORK. Don’t burn clutches up anyway. I just FINALLY got the bracket made for my PD/MZB coil/EEC. I don’t need to be making more work for myself by messing with the clutch cover! Look great though! Very nice!
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Looking at these, and how cool they are, I was thinking, "Why not weld five or six half round pieces to my original cover, drill them undersize, then cut it off with a thin tool, tap the bottom, drill the top to size and put a gasket or RTV it back together?” Then I realize, MORE WORK. Don’t burn clutches up anyway. I just FINALLY got the bracket made for my PD/MZB coil/EEC. I don’t need to be making more work for myself by messing with the clutch cover! Look great though! Very nice!
Thats exactly where I left it Brute.
Motivation is a rare comodity these days. with a pregnant crazy wife, and a 2.5 year old
(http://i13.photobucket.com/albums/a289/Motorrad/FINAL20DEPTH20INSTALLED20ON20THE20BIKE203_zpsbd89dcd6.jpg)
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Looking at these, and how cool they are, I was thinking, "Why not weld five or six half round pieces to my original cover, drill them undersize, then cut it off with a thin tool, tap the bottom, drill the top to size and put a gasket or RTV it back together?” Then I realize, MORE WORK. Don’t burn clutches up anyway. I just FINALLY got the bracket made for my PD/MZB coil/EEC. I don’t need to be making more work for myself by messing with the clutch cover! Look great though! Very nice!
When I get this done and all figured out, this will be a very easy mod to do as I will have the adapter rings available.
That is the hardest part of this project.
Remember, if I can do it, any half wit can do it.
I'm good with a computer and taking things apart but putting them back together? :roll:
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You know you want one..
(http://www.oem-cycle.com/forum/download/file.php?id=458)
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Last week I said your deadline was mid-this week......tomorrow is mid-week......where is my clutch cover Blaster!? :-D
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Wait, I shipped on Monday by Express, you haven't received it yet?
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Wait, I shipped on Monday by Express, you haven't received it yet?
NOOOOOO!! I have not recieved it yet!! Disatisfied customer alert!!! Feelings are hurt!! Its cool, you can send me another clutch cover set up with USMC 500 engraved on it along with your Hinson clutch basket.....
That will at least begin the healing process..... :-D
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Still waiting for quotes....
Also I have my second clutch cover cut up and at the machine shop for final machine thickness so I'm definitely in this for the long haul....
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Still waiting for quotes....
Also I have my second clutch cover cut up and at the machine shop for final machine thickness so I'm definitely in this for the long haul....
Hey.....don't change the subject there buddy......Hinson clutch basket.....mail.....tomorrow.......to me....... :-D
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Sorry, I already traded the Hinson to Motorrad for his OD gears...
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Sorry, I already traded the Hinson to Motorrad for his OD gears...
BOOM!!........did you hear that? that is the sound of you bursting my bubble. hahahahha
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this is an interesting thread, i am keen to know what they will cost. Keep us posted, if its within my budget i will have 2!
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Hey Blaster......where we at with this? I need this mod done soon......I think I might be needing a clutch in about 2 years. :-D
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Ahhhhhh..... Hmmmmmmm.... Duuuuhhhhhh..... Errrrrr.
The dog ate it :-D
Haven't gotten a quote yet from either source.
I may have to move on to another source.
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I have a spare clutch cover if you guys want it. It's been weld repaired from the infamous "rear brake lever stuffed into the side of the case" syndrome. I'll never use it. It would be perfect for a 2pc cover mod.
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I have a spare clutch cover if you guys want it. It's been weld repaired from the infamous "rear brake lever stuffed into the side of the case" syndrome. I'll never use it. It would be perfect for a 2pc cover mod.
throw that baby in the classifieds area.....Either in the "for sale" seciton if you want $$$ for it or in the new "free/barter" section if you wanna give it away......I'll be lookin... :-D
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found this
http://forums.mxtrax.co.uk/showthread.php/337945-kawasaki-factory-kx500-two-piece-clutch-cover-sr500
these clutch cover is one of the rare gp- factory parts used in the last 3 real factory kx500sr (sr means spezial racer) in 1990/91. ridden by dave thorpe, paul malin and billy liles. one of the 3 is still in germany in a private offroad museum. its not a 250-frame the frame is spezial design for the kx500 motor. gas tank waterpump and cylinderhead are designed from japanese engineers and the bikes handmade and tested in belgium at this time. :-) the gp-factory bikes of georges jobe , kurt nicoll and all the other great riders had allready 2 peace clutch covers since the first watercooled gp-kx500 in 1983.
at last my big question: why came this factory gp-bike of 1990 never in production??. why did not the 2 part clutch cover on production bikes??. that would have been in 1990, a great update.
but by the way, great work of you with your homemade 2 peace covers.. :-D
here some pics of the factory kx500sr of 1990 and the factory bikes and covers of ´84 and 88
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If you look good at the bikes of Nicoll and Malin or Lilles you see two different cover.
Nicoll's is just like a stock cover only 2 pieces, and those who were put in a parameter frame looks more like a 250 cover.
Johan Boonen had Factory engines as well, and his cover looks almost "self made". Look at the tube were cooland from the cylinder to the pump is.
And Thorpe was not a fan of the new age frame and rode later in the gp his old style frame. Maybe thats wy Kawasaki didn't put it in production.
Dutchie
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If you look good at the bikes of Nicoll and Malin or Lilles you see two different cover.
Nicoll's is just like a stock cover only 2 pieces, and those who were put in a parameter frame looks more like a 250 cover.
Johan Boonen had Factory engines as well, and his cover looks almost "self made". Look at the tube were cooland from the cylinder to the pump is.
And Thorpe was not a fan of the new age frame and rode later in the gp his old style frame. Maybe thats wy Kawasaki didn't put it in production.
Dutchie
yes... they have taken thorpe with a lot of money away from honda factory gp team. but thorpe was not realy happy with the Kawasakis. He then went back to honda in 91.
the different water pumps have to do with the exhaust laying. only at the 90/91 factory bike the other water pump is necessary. or can be built at all af / sf conversions to get to the cooling hose out of the way and get the pipe as close as possible to the cylinder. :-)
johan Boonen and daryl king were later also relatively successful with these bikes in gp.
But my question remains. why dont came this bike or the 2 peace clutch cover never to production? these parts were a few years for the factory team. why not also in a production update?
greetings to you from germany to netherlands 8-)
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Just an update....
Alward25 is sending me a inner clutch cover so I can verify the profile and hole position.
Don't want to make 10 adapters that don't fit right.
Plus I am waiting for quotes still....
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Just an update....
Alward25 is sending me a inner clutch cover so I can verify the profile and hole position.
Don't want to make 10 adapters that don't fit right.
Plus I am waiting for quotes still....
Thanks for keeping on top of this project! We all really appreciate it. :wink:
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Parts are in for verification
(http://www.oem-cycle.com/forum/download/file.php?id=698)
(http://www.oem-cycle.com/forum/download/file.php?id=699)
(http://www.oem-cycle.com/forum/download/file.php?id=700)
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(http://media.treehugger.com/assets/images/2011/10/Swedish-For-Speed-Bump.jpg.492x0_q85_crop-smart.jpg)
Oh wait, that's me.... :-D
I had a couple of people asking about these again so I will sit down and see if I can get this project done.
Sorry, I've been distracted with too many projects, rides, and the common anxieties of life :roll:
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Here is a handmade 2 piece cover a friend of me made last week
(https://scontent-a-ams.xx.fbcdn.net/hphotos-ash3/1234559_475033419271125_98746267_n.jpg)
(https://scontent-b-ams.xx.fbcdn.net/hphotos-frc1/598577_475033492604451_1400634951_n.jpg)
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Nice work.
How well does the rear brake lever fit?
Any pics of it mounted?
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lol someone please start making these im in dire need of an adapter.... or someone to write the program for the CNC Machine so we can all start making our own out of billet t6 or t7 aluminum.
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It all depends on how busy I am as to how much time I can devote to it.
I'm happy to provide a solid model of what I have.
I know it will work but I'm trying to refine it somewhat :|
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Sandblaster your awesome man keep up the good work! :-D I've been following this thread carefully and i totally understand the time and devotion it takes to make up one of these lol. That's exactly why i haven't even tried it. I've been looking for solutions to fix my clutch cover i cracked the other day :-( I have Welded it and still had a little leak so i decided to JB weld the rest of it. Everything holds.... :| but looks like its a frankin 500 and im a little sketchy about the JB weld. If anyone has any solutions im all ears. I love the idea of the 2 piece clutch cover!!!!
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Mike, I don't appreciate you one bit......in fact I loath the time its taking you to make this d**n thing........you better get on it and have a finished project by the time I get my motor done!!! :-D :-D :-D
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Ill take one and have a spare oem cover that got in a fight with the break pedal if you need.
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Mike, I don't appreciate you one bit......in fact I loath the time its taking you to make this d**n thing........you better get on it and have a finished project by the time I get my motor done!!! :-D :-D :-D
I feel so terrible.... :roll:
Ill take one and have a spare oem cover that got in a fight with the break pedal if you need.
Keep that cover, you'll need it..
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I finally spent some time on this project today.
I made another version to keep the cost as low as possible.
I think 5 profiles and all the holes can be machined in one set up, then the last step would have to be done one at a time unless a jig was made.
But for now, no jig..
I'm getting quotes on the material and the machining.
I hope to have some news fairly soon.
After a few of us verify the design viability then I will let every one know the cost.
Then, I will look at making custom covers and a slightly different design :-o
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By the way, if someone has a CNC and wants to whip up a batch of these to try out, let me know and I'll send you a CAD file 8-)
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Top view
(http://www.oem-cycle.com/forum/download/file.php?id=1417)
Bottom view
(http://www.oem-cycle.com/forum/download/file.php?id=1416)
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Top view
(http://www.oem-cycle.com/forum/download/file.php?id=1417)
Bottom view
(http://www.oem-cycle.com/forum/download/file.php?id=1416)
what do you think about making a coversion of ´88-91 kx 250 and k5 clutchcover conversion... they are very similar ...
the real big deal would be to get one of the factory 2peace-covers and copy it in sandcast... :-D
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I really feel like I need a 2 piece cover. Thanks for sticking with the project
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what do you think about making a coversion of ´88-91 kx 250 and k5 clutchcover conversion... they are very similar ...
the real big deal would be to get one of the factory 2peace-covers and copy it in sandcast... :-D
I looked at using the 89 kx250 clutch cover.
Unfortunately the kx500 cover is significantly bigger when you compare them side by side.
If you know anyone that has a factory 2 piece cover that would be willing to donate it so we could get it sandcasted let me know :lol:
I really feel like I need a 2 piece cover. Thanks for sticking with the project
No problem.
I hope this works :lol:
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Looks like a conduit nut
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is this a kx 450 bolt pattern?
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is this a kx 450 bolt pattern?
Yes.
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Thanks for your time and dedication to this project Mike! :-D
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The machine shop located across the street from my shop never gave me a quote on these.
So, I have another shop working up a quote.
The owner and I went to college together so maybe I'll get a quote.
I don't plan on selling these at a profit so whatever they cost will but what you pay.
Anybody have any guesses as to the price?
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We have a company that provides us with a few different billet parts we include in some of the fuel injection modules we sell at my work. I will drop them a line and see what they can do for us :-D
What material do you suggest using for this?
What is the rough dimensions for the piece of billet that will be used?
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I've got some 3/8" 6061 aluminum plate 8" x 8" coming for the first batch.
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a 2 peice clutch cover, an over drive 5th gear, a road registered rolling chassis KTM 450 conversion ( black plastics green decals and orange frame) and i think i will call it quits in the bike tinkering department. I dont think I could get a better bike than that.
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The progress on this has been slow...
But, the material is here and I have two quotes coming for the machine work.....
(http://www.oem-cycle.com/forum/download/file.php?id=1427)
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Hi, been watching this for a while now and very interested for my project :-) any idea on a price yet? Thanks.
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Can't seem to get anyone interested in making them up....
So, with very limited tools or skills I am going to attempt making one by hand.
(http://www.oem-cycle.com/forum/download/file.php?id=1601)
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I'm making one this weekend too with my limited tools and skills we shall see how it turns out
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Mine will take much longer to make and will look like junk...
But, at least I can prove the concept and show pics to potential machinists for production.
I'm sure yours will turn out much better then mine.
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Crazy really as i think there would be quite a demand for them as the brake pedal goes through it at every given chance and obviously for ease of changing clutch plates. What sort of machine would be required is it milling or lathe?
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Doordie had one of the slickest ones I've seen...although he was running a Rekluse...be cool to see someone come up with something similar.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/normal_PIC000040_zps46fe15f0.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/normal_PIC000040_zps46fe15f0.jpg.html)
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Crazy really as i think there would be quite a demand for them as the brake pedal goes through it at every given chance and obviously for ease of changing clutch plates. What sort of machine would be required is it milling or lathe?
Mill... I know some good cnc mill guys but I need someone to program it.
I use to use Smartcam 12 many years ago but I don't know anyone that has the software anymore and I probably have forgotten how to use it :roll:
Doordie had one of the slickest ones I've seen...but I remember him posting he had some trouble keeping it perfectly leak free sometimes, although he was running a Rekluse...be cool to see someone come up with something similar.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/normal_PIC000040_zps46fe15f0.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/normal_PIC000040_zps46fe15f0.jpg.html)
I'm going to use a kx450F cover with my adapter.
Then I need to find a oil temp gauge for the oil filler hole.
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I think i still might want to go this route.(http://i1240.photobucket.com/albums/gg485/alward25/kx500cover_zps983215ec.jpg)
Looks the most trick, but I am still exploring Sandblasters option.
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not bad....but after having a brake pedal dent and crack a cover before, if I was gonna put the time and effort into making one, the Lexan would be the way I'd go...won't break/crack/or dent...and I'd have a nice view.
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I agree Alward.
I like the look of that cover the best.
But as Foxx pointed out it has less clearance between the cover and the brake lever then the stock one.
While I like the look of the lexan I don't need reminders of how dirty my oil is 8-)
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I don't need reminders of how dirty my oil is 8-)
C'mon...don't you have money bags sewn into your pants as pockets?...keep that oil clean :lol:
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I do change my oil every time I ride.
I don't wear the same kind of money bag pants that you do but I do get my oil at cost :-P
But, with aluminum clutch plates it looks dirty in 5 minutes of riding...
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after just buying another truck....my money bags are more like coin purses for a couple months now :cry:
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the brake pedal clearance is an easy fix, Lexan scratches too.
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wasn't trying get into a debate at all with you Alex, but..
you can fix the clearance issue all you want...the problem still exists...the brake pedal is an issue and always will be no matter what kind of cover is in place, whether aluminum or Lexan, if it takes a hard enough hit, but aluminum bends and sometimes cracks, which can lead to a really bad oil leak as I found out...not fun when you're 20 miles from home and you just watched your oil pour out on the ground.
You have your reasons for liking aluminum, and I have my reasons for not.
I'll take my chances with the non-breakable Lexan, and make it home with a couple minor scratches. :-P
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wasn't trying get into a debate at all with you Alex, but..
you can fix the clearance issue all you want...the problem still exists...the brake pedal is an issue and always will be no matter what kind of cover is in place, whether aluminum or Lexan, if it takes a hard enough hit, but aluminum bends and sometimes cracks, which can lead to a really bad oil leak as I found out...not fun when you're 20 miles from home and you just watched your oil pour out on the ground.
You have your reasons for liking aluminum, and I have my reasons for not.
I'll take my chances with the non-breakable Lexan, and make it home with a couple minor scratches. :-P
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wasn't trying get into a debate at all with you Alex, but..
you can fix the clearance issue all you want...the problem still exists...the brake pedal is an issue and always will be no matter what kind of cover is in place, whether aluminum or Lexan, if it takes a hard enough hit, but aluminum bends and sometimes cracks, which can lead to a really bad oil leak as I found out...not fun when you're 20 miles from home and you just watched your oil pour out on the ground.
You have your reasons for liking aluminum, and I have my reasons for not.
I'll take my chances with the non-breakable Lexan, and make it home with a couple minor scratches. :-P
Wait till you see my cover. Will make lexan look like tissue paper
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looking forward to it....any hints?
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looking forward to it....any hints?
A friend of mine wore it in desert storm. And is made of titanium. And will stop multiple 7.62 hits
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well that certainly arouses the curiosity! :-D...when can we expect a preview?
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I was not trying to downplay the Lexan idea Fox. The stock style cast covers do crack if hit hard enough, I was looking to mill it out of something burly. My milling guy is a plastics and aluminum specialist and I was going to get his input on what would be best, a lexan version may be produced as well. More to come, I will have the money to throw at it soon enough.
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thanks Alex...sorry if I came across as a dick in any way...I wasn't trying to at all, sometimes I suck really bad at putting words together so that I don't sound like a jerk. If I ever do, please feel free to tell me to shut the "F" up. :-D
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I'm in for a solution to this. I have 2 cracked covers right now. I could try not to fall again but that's never gonna happen.
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
ditto my friend! :-D
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
Eat me :0p
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
Eat me :0p
Is this the moment when I did not thank everyone that there will be a big bunching of panties, OK,
Thanks to all, especially Motorrad, for all that you guys contribute. For keeping a bike alive that has not been produced for a decade!
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
Eat me :0p
Is this the moment when I did not thank everyone that there will be a big bunching of panties, OK,
Thanks to all, especially Motorrad, for all that you guys contribute. For keeping a bike alive that has not been produced for a decade!
Huh. No. I was just giving you hard time. Fight fight fight fight
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I know you did not mean anything by it, it is hard to add emotion to text. I have come across that way more than a few times, sometimes on accident :-D. Thanks for all you contribute.
Eat me :0p
Is this the moment when I did not thank everyone that there will be a big bunching of panties, OK,
Thanks to all, especially Motorrad, for all that you guys contribute. For keeping a bike alive that has not been produced for a decade!
Huh. No. I was just giving you hard time. Fight fight fight fight
and the fighting would finally end up like this... :-) fight and bite...
(http://images2.fanpop.com/images/photos/4200000/Itchy-and-Scratchy-the-itchy-and-scratchy-show-4201330-1024-768.gif)
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Here's what I think, and mind you this is only an opinion, and its mine. I have a two piece cover, its been posted on here a number of times and works like a dream, doesn't leak would make clutch change easy. OK, so I said would make clutch changing easy, but to be honest, I have never had to change a clutch in the field. i do the maintenance in the garage and hopefully won't have to in the field. I have a couple of pretty healthy running 500's one on Nitrous (actually I'm not using the one on Nitrous anymore but did for years) hillclimbing, this is a sport that is hard on clutches. so I guess what I'm saying, is other than the bling factor, the absolute need I don't think is there. If they could be produced reasonably inexpensively then yeah it would be a good deal. I have a ton of hours in mine, so unless you can find a cover that is off the shelf, like the 450 cover and build a ring like Sandblaster is going for, I think it will end up cost prohibitive.
If this all comes to fruition then I may be up for one as well, but for now I'm going to adopt the wait and see approach and hope something works out
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YUP!!!! 100% bling factor!!!!!!
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I had a chat with my dad this morning he works for a Canadian engineering company here in the uk. He said he could make a adapter plate quite easily and said it would be best as sandblaster suggested to use a clutch cover off another bike to save time. I don't suppose sandblaster could tell me the outside diameter of the kx450f clutch cover compared to the diameter of the kx500 casing after the top has been cut off? Saves me buying a load of clutch cases to try, thanks in advance :-)
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I just don't want another "brake pedal through the case" again. :-)
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i see more than bling factor. with the 2-peace cover you will never have to drain the cooling water , if you work on the clutch. that saves also lot of time for fixing other things on the bike.. :wink:
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i see more than bling factor. with the 2-peace cover you will never have to drain the cooling water , if you work on the clutch. that saves also lot of time for fixing other things on the bike.. :wink:
Which is really my point, if you do the maintenance you rarely have to get into the clutch, and with a two piece cover that is all you can get to, maybe if you remove the basket you could get to something else but it would be minimal, so yeah it is a bling deal
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Get me dimensions, I can have them waterjet and finish them on the mill or lathe :wink:
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I agree with Don 100%. The only people to see a real benefit would be the auto clutch users.
It's not a difficult modification, but requires multiple operations to do correctly. This drives the cost up.
So you spend the money and have a trick part that is heavier, has an extra place for an oil leak and has set up a failure mode for the cover itself. That nice, stiff, compound curved surface that got chopped off contributed to the stability of the kickstart bushing area of the cover. No bolt-on cover plate will restore the rigidity of the stock casting, which already has issues in that area.
Weld a 1/8 inch thick aluminum patch on the stock cover where the brake pedal wants to intrude. Take the money you saved and buy new tires. You'll go faster.
Just my opinion, I could be wrong. But I'm not.
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its the same thing with the comp-release-mod . the engine will always perform in the same way with or without it. :wink: its a little bit bling and makes starting easier. but if you know how to start an 500 without it, you
will not miss it.
i see only the time factor. with the one-piece-cover you have to drain the cooling water, remove the kickstarter , governor-cover and on some bikes also the pipe to remove the cover and see the clutch. that needs lot mor time as with an 2 peace-cover. a good race-mechanic could replace the complete clutch assembly in 10 minutes or faster.
for the case that the brake-pedal comes through the clutch-cover , you could easily replace the little cover without welding or buying a new one-peace-cover.
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Okay....sooooo, back to some productive conversation...it sounds like Roostius has a great idea to get things going as well. Does anyone have easy access to provide him with the measurements and dimensions he's requesting?
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Okay....sooooo, back to some productive conversation...it sounds like Roostius has a great idea to get things going as well. Does anyone have easy access to provide him with the measurements and dimensions he's requesting?
Email has been sent. 8-)
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Okay....sooooo, back to some productive conversation...it sounds like Roostius has a great idea to get things going as well. Does anyone have easy access to provide him with the measurements and dimensions he's requesting?
... soooo, here my realistic idea: a conversion of an 88-91 kx250 2piece-cover (or alternativ from 2007 kx125) with the kx500 cover (because, the same clutch is in both) .. in the way like sandblaster started with cutting and then welding together.
that will look like stock after a little bit mashining and sandblasting. at least comes the dificultest part: you need a company that is able to copy / reproduce it, for an fair price.
second idea : reproducing only the little part of the 250 covers with the "weld on adapter" as a conversion-kit or repair-kit for damaged kx500 clutch covers. for the reproduce you can contact some manufacturers like boyesen, that had this covers as aftermarket custom parts.
my thinking is ,for the bling factor it should not look like bad handcrafted with parts of diferent diameters ... it should look like there were never an other part like this before. :wink:
at the moment i personally dont have the possibilitys to do it, but in this way it is makeable.
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Update...
I will be sending Roost some files on Monday along with some materials :-o
There are a lot of other ideas for doing this.
I encourage everyone to pursue your idea and show us how you did it along with the results.
Like most of you I am no mechanical genius and I don't have deep pockets like Foxx does :lol:
I have to make things simple, easy, and cheap, so that I can do them.
The beauty of doing it like this is most of us have broken clutch covers that need to be repaired.
You can cut your broken clutch cover down, have the adapter welded on, get a stock or aftermarket kx450f cover and bolt it on and have some bling.
If and when you stick your brake lever through your clutch cover again, you simply order a another and be done with it.
The bling will be addressed more on the phase 2 adapters which I have not started so don't ask :wink:
I want to prove this concept first before we get carried away with a lot more time and expense.
There are a lot of good reasons for just repairing what you have (Cheap) or doing it some other way and I appreciate all the input.
But for now we'll see how this works and make changes as required.
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Update...
I don't have deep pockets like Foxx does :lol:
wow, that was way below the belt :-P
In all seriousness though, that is great news Sandblaster....believe me, I wish I had a 1/4 of the "shops" and "tools" some of you guys do....not too many of us could ever house a water jet, let alone afford one....and I think it's really cool for Roostius ,yourself, alward25 and everyone else to dedicate the many hours of work and time it takes, and share their progress, for all of "us" to have the opportunity to enjoy the outcome!
Thank you!
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Update...
I will be sending Roost some files on Monday along with some materials :-o
There are a lot of other ideas for doing this.
I encourage everyone to pursue your idea and show us how you did it along with the results.
Like most of you I am no mechanical genius and I don't have deep pockets like Foxx does :lol:
I have to make things simple, easy, and cheap, so that I can do them.
The beauty of doing it like this is most of us have broken clutch covers that need to be repaired.
You can cut your broken clutch cover down, have the adapter welded on, get a stock or aftermarket kx450f cover and bolt it on and have some bling.
If and when you stick your brake lever through your clutch cover again, you simply order a another and be done with it.
The bling will be addressed more on the phase 2 adapters which I have not started so don't ask :wink:
I want to prove this concept first before we get carried away with a lot more time and expense.
There are a lot of good reasons for just repairing what you have (Cheap) or doing it some other way and I appreciate all the input.
But for now we'll see how this works and make changes as required.
sandblaster my friend, if you have an 88-91 kx250 clutch cover in your junk piles, you could compare it directly to the k5-cover and you will see what i mean and how easy it could be done with the awesome factory-look . your version is a good start ,there is no question.
for my second idea as a weld on conversion or repair-kit, for all kx250´s 83-87 and kx500´s 83-2004,
it needs only one good used 88-91 kx250 cover for copy the outer cover plus the adapter ring in sandcast or maybe better: cnc-milled from a block as bling bling billet part . i prefer to one of these ways..
at least it is only money to make it real.
so guys, now i´m looking for 1 or 2 cheap and good used 2 peace clutch covers of the kx250 88-91 one for my 87 kx250 , the other for the k5-engine ... :wink:
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I don't have any older clutch covers right now but I may on Monday.
If I reel one in I will compare and see.
For some reason I think we did compare them at one time but we'll see :-o
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I don't have any older clutch covers right now but I may on Monday.
If I reel one in I will compare and see.
For some reason I think we did compare them at one time but we'll see :-o
at the moment are them hard to find. there are 2 or 3 250 outer covers on ebay,
but i need the inner cover for measurements to make the 500 conversion kit ...
aaaand i can bolt it directly without changes to the 87 250 engine. :-D as i fixed my 87 tranny last week i also found out, that the inner clutch gasket is the same 87-96 that gives me some options for the 250.
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It seems to me that the kx250 inner clutch covers were too short but I should know on Monday as I have set the hook on a 89 kx250 :-D
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It seems to me that the kx250 inner clutch covers were too short but I should know on Monday as I have set the hook on a 89 kx250 :-D
Perfect, I always have "feeling" it could fit a K5 :-D
dutchie
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It seems to me that the kx250 inner clutch covers were too short but I should know on Monday as I have set the hook on a 89 kx250 :-D
Some what explored:
http://www.kxriders.com/forums/index.php/topic,9917.0.html
Still hopeful this can be done!
DoldGuy
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It seems to me that the kx250 inner clutch covers were too short but I should know on Monday as I have set the hook on a 89 kx250 :-D
i dont think that the inner 250 cover would fit directly to the k5 without mods for waterpump and governor drive and the k5 kickstartshaft is also bigger diameter than 250 , but without a try we never will find out ... :-)
my thinking was to use the outer 250 cover and making cuttings on the right places to weld the cutted ring of the 88-91 250 to the k5 clutch housing and we can bolt on the 250 outer cover to the k5 .
without destroying one of the rare 88-91 250 inner cover could the needed weld on adapter copied without cutting and only measure the location of bolt holes and diameters. with the right tool on pc could made a program with the needed dimensions for a cnc-mill , find the right mashine shop and we have it... the outer cover could be easily copied with the cnc- mill . (or maybe a 3d-printer?? :wink:)
and like i said: at the moment i run a little bit out of my possibilities and it would give a very long session to make this adapter by hand in my garage. there is nothing that not could be made. it needs only time , money , the right material and gives lot of fun.
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The following pics are of a 89 kx250 clutch cover sitting on top of my cut down kx500 inner clutch cover.
(http://www.oem-cycle.com/forum/download/file.php?id=1624)
(http://www.oem-cycle.com/forum/download/file.php?id=1625)
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(http://www.oem-cycle.com/forum/download/file.php?id=1626)
(http://www.oem-cycle.com/forum/download/file.php?id=1627)
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(http://www.oem-cycle.com/forum/download/file.php?id=1628)
Looking close at the pics, you can see that the 89 kx250 clutch cover is slightly smaller then the KX500 inner clutch cover.
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(http://www.oem-cycle.com/forum/download/file.php?id=1628)
Looking close at the pics, you can see that the 89 kx250 clutch cover is slightly smaller then the KX500 inner clutch cover.
thats why the outer diameter of the clutch housing is a little bit cone formed on k5 and kx250 . but this diference is peanuts against the cover that you used before.. :wink:
this pic shows real good what i said and will try to make if i have the time and right material in hand.
now all can see , if it would be finished in this way it looks like it came from kawasaki-factory ... 8-)
and also no clearance-problem that would come with kickstarter or brake-lever by using an bigger diametered cover of an other engine.
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Well.... Get it done... I can't wait to see it :-D
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Well.... Get it done... I can't wait to see it :-D
in first i have some other more important projects, but stay tuned ... :-D
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That materials, prints, and sample parts have been sent to Roost.
In a few weeks or so we should get our first sample..
He has some good idea's that I will share later :-o
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About 2 days before Roost volunteered to machine some of the adapters I had started making a adapter by hand.
Poor mans water jet:
(http://www.oem-cycle.com/forum/download/file.php?id=1601)
Poor mans milling machine....
(http://www.oem-cycle.com/forum/download/file.php?id=1632)
Now I'm wondering if I should finish it or wait for a really nice one from Roost....
Yeah, I'm going to make a stab at finishing it :lol:
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Onya Blaster,mate you would fit in well in outback australia. A bush mill, have you tried the bush lathe? hand drill in a vise and a hand file or Dremmel if you wanna be fancy. Lucky theres no Occupational Health and Safety in my shed.
There was a TV show on here a few years back on Bush Mechanics, these guys are aboriginals and they were making brake shoes and clutch pads out of certain types of bush woods, was actually realy cool to watch as well as have a good laugh.
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Onya Blaster,mate you would fit in well in outback australia. A bush mill, have you tried the bush lathe? hand drill in a vise and a hand file or Dremmel if you wanna be fancy. Lucky theres no Occupational Health and Safety in my shed.
There was a TV show on here a few years back on Bush Mechanics, these guys are aboriginals and they were making brake shoes and clutch pads out of certain types of bush woods, was actually realy cool to watch as well as have a good laugh.
Oh yeah, I've done the bush lathe thing and much worse :-D
It's amazing what you can do when you have little to work with.
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Onya Blaster,mate you would fit in well in outback australia. A bush mill, have you tried the bush lathe? hand drill in a vise and a hand file or Dremmel if you wanna be fancy. Lucky theres no Occupational Health and Safety in my shed.
There was a TV show on here a few years back on Bush Mechanics, these guys are aboriginals and they were making brake shoes and clutch pads out of certain types of bush woods, was actually realy cool to watch as well as have a good laugh.
Oh yeah, I've done the bush lathe thing and much worse :-D
It's amazing what you can do when you have little to work with.
a bastard file is my best friend (when all my real tools fail)
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I have several bastard files.
Some are ancient but they still work 8-)
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About 2 days before Roost volunteered to machine some of the adapters I had started making a adapter by hand.
Poor mans water jet:
(http://www.oem-cycle.com/forum/download/file.php?id=1601)
Poor mans milling machine....
(http://www.oem-cycle.com/forum/download/file.php?id=1632)
Now I'm wondering if I should finish it or wait for a really nice one from Roost....
Yeah, I'm going to make a stab at finishing it :lol:
You could do some sweet port work with that thing Bra!
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Send me your cylinder and I'll show you some port work :wink:
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About 2 days before Roost volunteered to machine some of the adapters I had started making a adapter by hand.
Poor mans water jet:
(http://www.oem-cycle.com/forum/download/file.php?id=1601)
Poor mans milling machine....
(http://www.oem-cycle.com/forum/download/file.php?id=1632)
Now I'm wondering if I should finish it or wait for a really nice one from Roost....
Yeah, I'm going to make a stab at finishing it :lol:
...before you finish your version look at the clearance to kickstarter-swing and the brake pedal, if it would be installed on the bike. i think this two points are very important.
now you are 2 steps before me :-D... the men of steel is now the man of aluminium ... :lol:
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Yep, I already checked clearances and I'm good 8-)
At least I think I'm good.
But I could be bad.
We'll see :-D
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Done with the poor mans water jet and milling machine.
I still have to drill and tap the holes, sand and polish, then get it welded.
(http://www.oem-cycle.com/forum/download/file.php?id=1633)
(http://www.oem-cycle.com/forum/download/file.php?id=1634)
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Poor mans milling machine in action.
http://www.youtube.com/watch?v=Qp2qYJk_VAY&feature=youtu.be (http://www.youtube.com/watch?v=Qp2qYJk_VAY&feature=youtu.be)
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that's a fine lookin unit.
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that's a fine lookin unit.
That's what she said
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Regardless of what she says, there is a lot of chatter and it has a tendency to jump out of your grip,
This only happened once and I didn't like it :-(
http://www.youtube.com/watch?v=X-gkWTEL7aI&feature=youtu.be (http://www.youtube.com/watch?v=X-gkWTEL7aI&feature=youtu.be)
If your gonna try it, just be careful 8-)
This is still rough but it is taking shape.
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Yep, I already checked clearances and I'm good 8-)
At least I think I'm good.
But I could be bad.
We'll see :-D
the bad boys have always a good core inside ... :wink: ...
sounds good.. cant wait to see the finish of yours..
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Now I'm waiting for my KX450f clutch cover to come in so I can confirm the geometry and then get it polished, drilled, tapped, and welded on.
(http://www.oem-cycle.com/forum/download/file.php?id=1644)
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A little more progress.
I've got to get some socket head cap screws but you get the idea.
(http://www.oem-cycle.com/forum/download/file.php?id=1651)
(http://www.oem-cycle.com/forum/download/file.php?id=1652)
Now I need to verify that I correctly calculated the depth by fitting it to my bike.
Once that is done then I can have it welded.
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i must get onto this when i get some time
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That is looking really good!
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Thanks guys.
Yeah I'm starting to get excited about it.
After getting one hand made to this point I can see where I can make some small improvements so I told Roost to hold off until I can make a few changes.
I'm trying to have them made as easy and as little machine time as possible.
So as soon as I get one of my clutch covers back from a loan I will make the final print and shoot it off to roost.
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Thanks guys.
Yeah I'm starting to get excited about it.
After getting one hand made to this point I can see where I can make some small improvements so I told Roost to hold off until I can make a few changes.
I'm trying to have them made as easy and as little machine time as possible.
So as soon as I get one of my clutch covers back from a loan I will make the final print and shoot it off to roost.
Gee no pressure or anything
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No names were used to protect the guilty. :lol:
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No names were used to protect the guilty. :lol:
Good I wouldn't want anyone to know or was me
:| :| :|
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Shame on all this name calling. :evil:
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No names were used to protect the guilty. :lol:
Good I wouldn't want anyone to know or was me
:| :| :|
No worries... it's all in good fun... :-P
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Always waiting on Motorrad it seems like. Doesn't matter what it is :P
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wont you end up with 2 oil fill holes?
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Yes, that's the beauty....
Can you say oil temp gauge? :-)
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yeah thats what i was thinkin but what type would you use?
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Still looking for the right one :-)
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A little more progress.
I've got to get some socket head cap screws but you get the idea.
(http://www.oem-cycle.com/forum/download/file.php?id=1651)
(http://www.oem-cycle.com/forum/download/file.php?id=1652)
Now I need to verify that I correctly calculated the depth by fitting it to my bike.
Once that is done then I can have it welded.
+1 at this point. :-) show pics of the bike-fitment .. :wink:
i think by copy the outer cover on a mill, could the additional oil cap of the 450 be removed, if its not needed ...
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Looking GOOD :-D
Dutchie
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It was time to change the oil on my Sand machine so I decided to check my fitment..
From the factory
(http://www.oem-cycle.com/forum/download/file.php?id=1657)
(http://www.oem-cycle.com/forum/download/file.php?id=1658)
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On goes the cut down clutch cover (Now a inner clutch cover)
(http://www.oem-cycle.com/forum/download/file.php?id=1659)
On goes the outer clutch cover and adapter:
(http://www.oem-cycle.com/forum/download/file.php?id=1660)
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On goes the kick lever and the rear brake lever
(http://www.oem-cycle.com/forum/download/file.php?id=1662)
Just barely...
(http://www.oem-cycle.com/forum/download/file.php?id=1663)
(http://www.oem-cycle.com/forum/download/file.php?id=1664)
While it does not rub, it is close, so I may slightly bent my brake lever out, then again probably not cause I'm lazy.
I also found some hidden dirt and grease on my bike.... I was shocked :-o
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that looks good, pedal is a little close....I zip-tied a piece of inner tube to the back side of my brake pedal to help create a cushion/buffer.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/jh_zps58e70740.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/jh_zps58e70740.jpg.html)
it's nothing pretty, nothing fancy...but better than metal hitting metal if it takes a hit.
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Where did the dirt and grease come from!? It's not like you ride it lol
That is a snug fit but looks factory. Nice work.
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that looks good, pedal is a little close....I zip-tied a piece of inner tube to the back side of my brake pedal to help create a cushion/buffer.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/jh_zps58e70740.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/jh_zps58e70740.jpg.html)
it's nothing pretty, nothing fancy...but better than metal hitting metal if it takes a hit.
I like the idea of the cushion.
I originally had another 1/8" of clearance from the inside of the rear brake lever to the outside of the clutch cover.
The problem is, the thinner I make the adapter, the thinner the bolt tangs are.
If I go to thin the bolt tangs will strip easily so I'm trying to find a balance...
Might even add a spacer to the inside rear brake lever and push it out a bit :-)
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knock on wood it hasn't really been "put to the test" yet, it has fallen over gracefully on it's side once, and it did just fine...but as you know, if it takes a hard enough hit, it won't matter what's behind it for a buffer.
I understand your dilemma about the adaptor and the tangs...but knowing you, you'll come up with a solution.
EDIT...I've actually been using a HEAVY gauge o-ring behind the brake lever as a spacer with decent results so far.
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On goes the kick lever and the rear brake lever
(http://www.oem-cycle.com/forum/download/file.php?id=1662)
Just barely...
(http://www.oem-cycle.com/forum/download/file.php?id=1663)
(http://www.oem-cycle.com/forum/download/file.php?id=1664)
While it does not rub, it is close, so I may slightly bent my brake lever out, then again probably not cause I'm lazy.
I also found some hidden dirt and grease on my bike.... I was shocked :-o
gentlemen clap your hands for sandblaster. we have the first practicable solution. :-)
mike do you thought of cut down the inner cover a little bit more instead of the adapter ring, to eliminate the clearance problem to the brake?
here is a pic of billy liles 1990 / 91 kx500sr to comparing .
(http://www.mxclassicracing.com/images/dsc0148_579.jpg)
http://www.mxclassicracing.com/images/dsc0148_579.jpg
if you look good, it seems that the engine was the next step in evolution and they used the smaller bigger diameter basket of the 92-04 kx250 to get the engine smaller. the outer cover and waterpump looks also like later 250 parts like dutchy said in a former post.
in the next time i will try the fitment of an 250 inner cover from my 96 kx360 big bore engine to the k5-engine. i am excited how close the covers would be in direct comparing.
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Mr. Moto...
I have been scratching my head over this for some time.
I really hate to cut the adapter ring any thinner.
I could go a little thinner but not enough to make a practical difference.
Don't get me wrong, every little bit helps but I really want to keep all the strength in the adapter that I can.
Machining the inner clutch cover down is also not a good idea because I'm already as thin as I can go without cutting onto the governor area.
However... I came up with another solution this morning :wink:
I will take another look this morning and see if it will work.. But I think it will.
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If you have clearance you could machine the cover mating surface down a bit, it looks like the tabs are pretty thick, or take the ring down and use steel inserts to prevent stripping. or make it easy on your self and bend the brake lever
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Thanks Don.... You blew my big surprise :-D
Yes, that is exactly where I was going with it.
Of course, that adds one more machine process, and that adds money.
My original adapter was much more elaborate and would look really cool but it would be much more expensive so I have done everything I can think of to make it as cheap as possible yet still acceptable for aesthetics.
Again, trying to find the balance with cost conscious riders in mind.
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Thanks Don.... You blew my big surprise :-D
Yes, that is exactly where I was going with it.
Of course, that adds one more machine process, and that adds money.
My original adapter was much more elaborate and would look really cool but it would be much more expensive so I have done everything I can think of to make it as cheap as possible yet still acceptable for aesthetics.
Again, trying to find the balance with cost conscious riders in mind.
mr. sandblaster..
you do really great work with this project.. :-)
but this are all facts, that i not can see only from the pics.. only you are the man with the parts in hands. and only you could figure out, what will work best with it. i can only help a little bit with my logical thinking :wink:
and 100% agreed is : cheapest and easiest solution at this point is bending the brake lever .. :-)
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cheapest and easiest solution at this point is bending the brake lever .. :-)
Maybe 8-)
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the only thing about machining the cover, if you ever broke one you would have to machine it as well. If it was me I would take the most difficult route and bend the lever a little :wink:
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the only thing about machining the cover, if you ever broke one you would have to machine it as well. If it was me I would take the most difficult route and bend the lever a little :wink:
we could write a big book of pros and cons between mashining the cover or bending the lever. the fact is to find the compromise between, to hold the costs on an acceptable level... 8-)
quote author=sandblaster link=topic=11287.msg101659#msg101659 date=1393005940]
cheapest and easiest solution at this point is bending the brake lever .. :-)
Maybe 8-)
that sounds like a little surprise that you plan to make ... :wink:
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Ok, this shows the new clearance.
This time I bolted the inner clutch cover down.
Yesterday, I had it sitting loosely on the engine (Mistake).
I also took Foxx4Beaver's advice and put a small O-Ring behind the rear brake lever which helps push the lever further from the case.
Even if you push the brake lever as far as you can toward the engine, it still does not hit.
So, I am happy with the results and will have my adapter welded to the inner clutch cover.
(http://www.oem-cycle.com/forum/download/file.php?id=1665)
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without little fails is developing solutions much to easy... :wink:
looks great .. :-D
... that gives me a lot ideas with the root that i still want to go on my own projekt.. but now is time for top secret till i find the time and can work on it... :wink:
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Tonight I've been searching the net, this site and mine computer for side covers of 250's and 500's.
I think the "250" cover of Liles kx500sr is a special 500 cover.
The upper oil plug is in a angle and a bit more to the back.
With a 500 the waterpump and coverner are at a angle, 250 almost straigth down inline.
With Sandblasters option we AF guys could weld the stock filler plug hole for more clearence for the exhaust.
Looks like you gave me some work to do Sandblaster :mrgreen:
Dutchie
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I want one of these covers!!!!!!
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As soon as we get the initial adapters back and we work out a good method for doing everything and we will make these available.
Eventually I can see making our own customized covers but still using the KX450F template so that you can run either... With punisher skulls, talk to the pipe, and lexan windows, ect
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This is the tits
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Tonight I've been searching the net, this site and mine computer for side covers of 250's and 500's.
I think the "250" cover of Liles kx500sr is a special 500 cover.
The upper oil plug is in a angle and a bit more to the back.
With a 500 the waterpump and coverner are at a angle, 250 almost straigth down inline.
With Sandblasters option we AF guys could weld the stock filler plug hole for more clearence for the exhaust.
Looks like you gave me some work to do Sandblaster :mrgreen:
Dutchie
thats what i tried to say.. :wink: ...its a full gp-factory-bike. it seems that this engine is next step of evolution, that never came to production.
it looks for me that it use the basket like the later 250´s for an smaller engine. waterpump is also later 250 (92-2004).. the factory has much more possibilities to do special engine parts , like we can dream of... :wink:
but we can look at it for inspiring our mind... :-)
the single pic from the first post here:
(http://forums.mxtrax.co.uk/attachment.php?s=2f0ef5a11b2d31649fad87b593c22073&attachmentid=101461&stc=1&thumb=1&d=1359441606)
here is a view to kurt nicolls 88 kx500sr ... if you look good, youll see that it use the newer kx500 engine with a very similar outer cover like the 88/89 kx250´s
and that is, what i want to have at least...
(http://www.mxclassicracing.com/images/kawasakikx500sr88011_579.jpg)
http://www.mxclassicracing.com/images/kawasakikx500sr88011_579.jpg
and kurt nicolls 87 kx500 sr full factory bike to show the cover on the older engine
(http://img.webme.com/pic/d/der-motopunk/87kx500sr-kurt-nicoll.jpg)
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Those look great.
I double dog dare you to make one :-D
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Those look great.
I double dog dare you to make one :-D
we´ll see ... :-D ... first i have to do projects with more priority ...
just caught this one on ebay. a very rare brand new ´86 kx500 cylinder head ..discontinued by kawasaki since long long years...
i say the deal of the year ... 8-)
(http://img.webme.com/pic/d/der-motopunk/foto0141.jpg)
now i have the option to use my k5-engine also in the 87-frame.
next thing is to find an good used 88/89 inner and outer clutch cover, when i have my bikes ready for the new season . its like finding a needle in a hay-barn ... but anywhere out there is the one, that i´m looking for. i feel it :-D
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its like finding a needle in a hay-barn ... but anywhere out there is the one, that i´m looking for. i feel it :-D
Just use a giant magnet or your x-ray vision... You'll find one :lol:
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next thing is to find an good used 88/89 inner and outer clutch cover, when i have my bikes ready for the new season . its like finding a needle in a hay-barn ... but anywhere out there is the one, that i´m looking for. i feel it
if you wernt on the other side of our globe I would donate one to you. I have a fairly decant one I was saving to make one with, but have never gotten around to it but now am waiting for these to be on the market instead.
or this one looks better than mine
http://www.ebay.com/itm/Kx-250-clutch-outer-case-cover-and-water-pump-assembly-Fits-88-89-kx-250-/231166987957?pt=Motorcycles_Parts_Accessories&hash=item35d2a04eb5&vxp=mtr#ht_44wt_1022
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I'd grab that one if I needed it.
That's a good buy.
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its like finding a needle in a hay-barn ... but anywhere out there is the one, that i´m looking for. i feel it :-D
Just use a giant magnet or your x-ray vision... You'll find one :lol:
aluminium is not magnetic... :lol:
next thing is to find an good used 88/89 inner and outer clutch cover, when i have my bikes ready for the new season . its like finding a needle in a hay-barn ... but anywhere out there is the one, that i´m looking for. i feel it
if you wernt on the other side of our globe I would donate one to you. I have a fairly decant one I was saving to make one with, but have never gotten around to it but now am waiting for these to be on the market instead.
or this one looks better than mine
http://www.ebay.com/itm/Kx-250-clutch-outer-case-cover-and-water-pump-assembly-Fits-88-89-kx-250-/231166987957?pt=Motorcycles_Parts_Accessories&hash=item35d2a04eb5&vxp=mtr#ht_44wt_1022
the cover looks real good. ... but like you said its half around the globe and i have to watch out, that i´m not running out of my little amount of money for my other projects, when i buy parts all over the world for expensive shipping and customs clearance costs. usa was always the bigger market for bikes and parts as germany and europe and so it is always a little pokergame... :wink:
toby .. would you shoot me a pm with a pic of yours??
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OK Sandblaster... let me me know where to send my parts and check! lol! that looks AWESOME!!
WOW!
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Made a little more progress today making a weld fixture to keep the adapter from warping during weld.
(http://www.oem-cycle.com/forum/download/file.php?id=1678)
(http://www.oem-cycle.com/forum/download/file.php?id=1679)
(http://www.oem-cycle.com/forum/download/file.php?id=1680)
Next I'll have my buddy plasma cut the ID and trim up the OD.
Then I'll have him surface grind the side that sits against the adapter 8-)
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When I did my 2 piece, I just went for it. Welded it,ground it, cleaned it and installed it. No warpage or leaks. Seems like there is enough radiused edges to keep it flat.
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Your success is most likely due to your aluminum welding skills.
I have none... My welding buddy does not weld aluminum very well but he tries :-)
This may be over kill... then again maybe not... My adapter is only 1/4" thick...
I'm sure Larry, Motorrad, or some of the others here could do it but I have to make due with what I have to work with.
I even thought about using my clutch cover as the fixture but decided it wouldn't be stable enough... Again, I'm sure this is over kill but I want to give this project every chance of success.
I have 3 clutch covers that need to be fixed, I'd like to be set and ready to go from the very first try.
Who knows, perhaps I'll offer a finished product if I get good enough so as to bring down the cost :-o
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I had a friend weld for me. Maybe a bad case half would be good to secure to while welding. I have one but did not think to use it. Thanks for the great parts.
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I have a set of junk case halves if they are needed. I just keep them around for frame mockups.
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Found this cover https://picasaweb.google.com/102067261144953476086/ClutchCovers#5989268830144816242 (https://picasaweb.google.com/102067261144953476086/ClutchCovers#5989268830144816242)
(Still try to find how to post pics from picasa.)
It's From Paul Malins KX500SR in 1991. It has "the" elbow of the cylinder on the water pipe wich than runs to the rear of the cylinder.
Does anybody knows wich cover this could be?
Dutchie
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(https://lh4.googleusercontent.com/-1EFgP_NcADk/Ux4oRL0Z5HI/AAAAAAAAAZo/4cmWPEoUVFk/s640/Cover%2520Malin.PNG)
looks a little bit like a 125 outer cover... but at least i think it is full factory... by the way, i dream to have one of these factory pipes... :-D
dutchie click with the right mouse button on the pic .than on the list click "grafik info". copy the link and you can post the pic directly here with the insert-image function... :wink:
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Here is the test adapter bolted to the jig as it is back from surface grind to make sure it's flat.
(http://www.oem-cycle.com/forum/download/file.php?id=1700)
Here we are ready for weld.
(http://www.oem-cycle.com/forum/download/file.php?id=1701)
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Finally got the clutch cover adapter off to the weld shop today....
I should have it back within a week or so...
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Finally got the clutch cover adapter off to the weld shop today....
I should have it back within a week or so...
which weld shop :|
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Seagull express welding services :roll:
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Seagull express welding services :roll:
EEEK
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How will he get better if I don't let him poop on my parts once in a while?
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How will he get better if I don't let him poop on my parts once in a while?
That seagull should practice on some scrap aluminum not on your clutch cover lol
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Cast aluminum stuff is always iffy, particularly when it has been soaking in oil. Or anything really. Salt water is ugly too with salt crystals imbedded in it. He needs to practice on old crappy cast, not just practice!
Just got my old 1967 Miller 320 AB/P going again Saturday. I lost the HiFreq a while back. Thought it was one thing but turned out to be another. Just glad to get it going again for a couple hundred. Was thinking for a bit that I would have to bag it and either buy another AC Tig or just pay someone to do my stuff. :x New inverter ones have some great features and do not weigh much compared to my beast at about 1000 LBS. would clear out a little shop space as well but then again, I own this one. :-)
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How will he get better if I don't let him poop on my parts once in a while?
for welding it has to be metallic clean. any little oildrop is not good in the welding area and also important, the right heat treatment before and after welding...
let´s wait, what you finally get back from the welder... :wink: ...
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blast the case bare with glass, then soda, then bake it on a 10$ walmart hot plate until it smokes out all the crud from the bolt holes. weld it while its hot. :wink:
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You are so right Roost ... I did some research last night and you are spot on.
Then again I would expect nothing else from you :-D
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You are so right Roost ... I did some research last night and you are spot on.
Then again I would expect nothing else from you :-D
sympatic people, who sharing this knowledge are hard to find.. :-)... the big trick is, that it looks after welding and following processes like a non welded piece... 8-)
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Since my shop was broke into I have been really set back in all my projects.
The bike that I was using to test fit the two piece clutch cover on was stolen so I had to come up with another test fit method.
This should do nicely.
Junk case, junk trans shaft, and a junk clutch basket...
(http://www.oem-cycle.com/forum/download/file.php?id=1810)
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After weld.
(http://www.oem-cycle.com/forum/download/file.php?id=1821)
And does it fit?
(http://www.oem-cycle.com/forum/download/file.php?id=1822)
Good!
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New bearings and seals... Install the inner clutch cover
(http://www.oem-cycle.com/forum/download/file.php?id=1874)
Nothing binding...
Checking the clearance
(http://www.oem-cycle.com/forum/download/file.php?id=1877)
(http://www.oem-cycle.com/forum/download/file.php?id=1878)
(http://www.oem-cycle.com/forum/download/file.php?id=1879)
Looks good with plenty of clearance 8-)
Looks like I might be able to take it for a test ride this week before I take it to the dunes.
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That came out great. Wouldn't know it wasn't factory.
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Just don't look too close :lol:
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Just don't look too close :lol:
This really did come out great! Give yourself the credit you are due! :mrgreen:
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It really does look good, if you raise the brake pedal so it is level with the footpeg will it still clear? I couldn't get used to the brake pedal being that low. did you find somebody to build the adapter rings? if so that could be a very easy modification, buy the ring, cut the case, have the ring welded, and buy a 450 clutch cover, piece of cake.
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Clearance? Check!
What I did was adjust the rear brake set screw as far up as it would go, then I pushed up on the rear brake lever as far as it would go so you could see..
(http://www.oem-cycle.com/forum/download/file.php?id=1880)
(http://www.oem-cycle.com/forum/download/file.php?id=1881)
I think it fits as well if not better then the stock cover.
In fact, one my next one I will make the adapter ring about 1/16" thicker then I did this one.
When Roost slows down a bit and has a little extra time he is gonna water jet some rings for us.
You will have to cut your own cover, weld the ring, and tap some holes.
Roost is gonna water jet the tapped holes so all you need to do is tap them.
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Remember, I made this ring on my drill press with a carbide cutter free hand.
If you don't want to wait for Roost to make you one all you need to do is get a KX450F clutch cover.
Trace the perimeter on a piece of 1/4" aluminum.
Machine your KX500 clutch cover down so that it is about 1/4" below the surface of your water pump area (1.600" or so)
Then place the adapter over the hole in your KX500 clutch cover and trace the hole.
Cut is out with whatever, I used a jig saw.
Drill it and tap it.
Weld it.
Ride it.
Some of you guys could do it very quickly.
It took me forever just to figure out what I wanted because I have little to no idea of what I'm doing.
I need to ride it hard for a while to be sure there is no glitches but so far I am very happy with the results.
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d**n fine work SB. Just goes to show that you don't need the latest and greatest tools and equipment to do the job right.
I knew you could custom fab sandblaster :D It doesn't matter how long it takes as long as you're happy with it in the end.
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Thanks...
Now I'm debating if I want to make another by hand for my K5BC or wait for Roost.... :lol:
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Since I have a 2 piece clutch cover..... and it uses a kx450f cover.... and I have a Hinson clutch basket.... I was thinking about this...
(http://www.oem-cycle.com/forum/download/file.php?id=1994)
In fact, I could get a Pro Circuit cover like this...
(http://www.oem-cycle.com/forum/download/file.php?id=1995)
Then I could mix and match depending on my mood :D
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I think I will run this one for a while...
(http://www.oem-cycle.com/forum/download/file.php?id=2166)
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Very pretty.
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I have a budy that has a cnc controlled plazma cutter I could ask him how much he would charge if I had him make a few and if I had the cad file
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What is the accuracy and surface finish of the plasma cutter?
I can compensate the CAD file if I know.
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Here is his Facebook page https://m.facebook.com/profile.php?id=264396801739
You can look at his other work. Sounds like he would charge me almost nothing to make them I would just have to get him the cad design to lock in a price and find a place to buy the aluminum
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I sent him a pic as well as some questions.
As soon as he gets back to me I'll post what I find.
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tell him chris fuller sent you to him he is the owners cousin and he is my contact for getting the cheap pricing. basically he said that if i wanted a really really cheap price i could come over and he would setup the plazma cutter and i would just run the parts on it. so he wouldnt have to charge me for the time running it.
and i found this for mottorad
http://www.walmart.com/ip/29972902?wmlspartner=wlpa&adid=22222222227020560741&wl0=&wl1=g&wl2=c&wl3=52426055895&wl4=&wl5=pla&wl6=79504382895&veh=sem
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Interesting... Didn't know that Walmart sold bike parts.
Their price is the same as the lowest sellers on eBay.
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Interesting... Didn't know that Walmart sold bike parts.
Their price is the same as the lowest sellers on eBay.
neither did i but google led me there and all i could do was scratch my head. im tempted to order one from walmart just to see if its made from paper or plastic
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Exactly what I thought...
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And blaster if you get some made put me on the list to get one if you don't mind
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If we can get them made at a reasonable cost I will post the info for everyone to get one while the getting is good :-o
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so what are you using on the stator side ? matching covers??
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One side at a time :lol:
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(http://i.imgur.com/c1IJd75.jpg) brother layed my bike over so I need a new clutch cover asap lol
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I have sent the CAD file to several vendors.
Only one has sent back a response and the price was very high....
A member of this site will make some for us when he has the extra time and they will be really well priced but he is a very busy guy...
No pressure Roost :-D
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Roost roost he's our man if he can't do in no one can GOOOO ROOST!!!!!
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Figure me for one if thats feasible, thanks!
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(https://8vrbew.dm2301.livefilestore.com/y2pdbpGFLfZ3tD0JlDgND7QNu6zRKfudExe4kQP1_c81VbX-pRdynmy18JYHep6ZnNozl-JnZ3bS6MU6Z_KpJo-dDMj62NlfgjIuZMoh83aZqw/20141031_144835109_iOS.jpg)
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Are anyone making these for other people? I'd be down for 2 of them providing they aren't cost prohibitive.
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I spoke to Roost today and he beat me to posting his pic :-D
Roost will be making 2 piece clutch covers complete.
You will need to send him your clutch cover.
Prices and details are not available yet. :|
The adapters by themselves will be available for about 60 plus shipping.
The first batch was made from 3/16" not the 1/4" we wanted... :oops:
But I think they will still work.
As soon as I get my hands on my batch I will give it a good try and see what happens.
I'm ready, where's my adapters??? :lol:
(http://www.oem-cycle.com/forum/download/file.php?id=2708)
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Count me in for an adapter when you get one my T4 needs one.
I finally got around to finishing my first attempt at one I started for my bike about 4 yrs ago I used some pretty rough old covers so hard to make look to good but proved for Motopunk? that the 88 and 89 250 covers work great
(http://i164.photobucket.com/albums/u11/Stevejasper_2000/P1030606_zpsde6b4e3d.jpg) (http://s164.photobucket.com/user/Stevejasper_2000/media/P1030606_zpsde6b4e3d.jpg.html)
(http://i164.photobucket.com/albums/u11/Stevejasper_2000/P1030605_zps208cf78d.jpg) (http://s164.photobucket.com/user/Stevejasper_2000/media/P1030605_zps208cf78d.jpg.html)
c
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Looks great... Nice job.
We knew it could work.
The reason I chose the adapter I made was so that we could use the KX450F covers and it should be less work then using the one you did...
And the covers are relatively cheap and certainly easy to find.
But yours sure has a nice factory look.
Congratulations on a job well done.
Post some pics when you get it mounted up.
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If there was a drawing for that 1988-89 250 pattern I could slip some on the next sheet also. :wink:
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Dont like the crf cover having no oil level window
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I don't like CRF covers on my green machine either which is why I used a KX450f cover :-D
But I would like a window :|
Then again I change my oil so often that I really never look at it :-o
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Count me in for an adapter when you get one my T4 needs one.
I finally got around to finishing my first attempt at one I started for my bike about 4 yrs ago I used some pretty rough old covers so hard to make look to good but proved for Motopunk? that the 88 and 89 250 covers work great
Nice job on your covers Toby. Did I read your post right? Are you going to put one on your tecate 4? How are you going to do that? I see the clutch release and rod being fairly complex. The KX's seem a lot less involved
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I don't like CRF covers on my green machine either which is why I used a KX450f cover :-D
But I would like a window :|
Then again I change my oil so often that I really never look at it :-o
The main reason i like a window is after having a cr500 supermoto nearly kill me due water pump seal fail /overfill the tranny and pour creamy oil over my back tyre
Since then i like to glance at a oil window before i ride
on the dirt not a problem
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Dirk I have 1 T4 with a Kx 500 in it . I have looked at how to modify the T4s covers but they would take more machine work that I am capable of.
Roost the 88 covers wouldn't really need a adapter all you need to do is mill the cover down the same as the 250s then build up some tabs for the bolts they are basically the same shape and size as the 500s but the 250 covers are pretty scarce and you cant get cool aftermarket covers I like sandblasters plan I just did this one cause I had it laying around.
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as for the window issues you could have whoever installs your adapter remove the old window port from the 500 cover and weld it on your 450 cover of choice
on another note make sure you find a good welder or send it to roost for a install my cover was the worst casting ive welded on I fought it the whole way it was full of crap
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I'd looked for those old covers a couple years ago too and just bailed on it. haha
The cases need to sit on a hot plate and bake the oil out of them before welding/
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If guys want the sight glass bad, send me the aluminum, not magnesium 450 cover they'll be using and I can install their old glass in it.
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I'm late to the dance here, are any of the after market companies building an aluminum cover or are they all magnesium?
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Best I can tell Hinson and pro circuit covers are aluminum. Does that sound right?
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Are the adaptors available yet?
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Very soon....
Roost let me know that the final production run would be done in about 2 weeks so I should have them in about 3 weeks.
I'm not sure how many will be available but as soon as I know you will know.
I currently have 3 spoken for and I'm thinking we will probably get about 10 of them in.
So we will see.
I have another victim ready to go to the machine shop..
(http://www.oem-cycle.com/forum/download/file.php?id=2819)
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I have 2 covers that need the mod i can send as soon as u give the word
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Send me your covers?
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Send me your covers?
Not after :wink:
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I would rather just buy one and do the work myself :-D
No offense
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That's good because you wouldn't want to pay my bill :-P
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I have some billet clutch covers here at the moment. I'm going to try and install the window in one.
They are wider than stock covers so the 3/16 flanges the boys had cut may work out perfect here.
Bro is to weld one tomorrow morning, then I'll set it back up on the mill, locate the window and poke a hole in this billet one.
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That's gonna look great..
Post some pics..
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So far I have 5 solid commitments on the adapters.
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We got feeding cattle and preparing the yard for winter, took the transmission shuttle out of the loader and buggered around with it until we ran out of time to weld. Tonight tho!
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Gotta be getting cold up there.....
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its hanging around 20f, I can live with that. Its the impending -45f thats got me worried :roll:
I'm not happy with the fit of just jamming this in, I'm going to make a proper little housing for it.
(https://8vrbew.dm2301.livefilestore.com/y2pit6r3VpTUc00QV4aKgKJIsLp4YWj5wVv1m2BXSobgYz9gn3uaJhIZWiRE2hLh2aRuzrMy5UzJWUJWHmh95M56r4FcYvd1AnRZ7gcyEeTYQY/IMG_4129.JPG)
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did you machine that? thats super impressive! nice job.
what kind of cnc?
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better!
I didn't make these, just modifying them.
(https://8vrbew.dm2301.livefilestore.com/y2pmruIMt0pSsCg9hGj0qZTemiWuYByXaR2N9xLtJBDbduW3x_23Rs0syCAjEu2fYkvocsZUfrTtgJif7S3K2i1qRKt_S8SmC8hozwcxcVwebI/IMG_4137.JPG)
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Wow...
Looks great... 8-)
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without gaskets on the case or the cover I have .380" clearance from the bolt head (.100" wider than engauged pressure plate) on the stock 450 cover and .450" with the billet cover.
I measured the billet cover to be .080" wider than a stock case when installed on the 3/16" adapter, again without gaskets. The 450 cover sits -.040" narrower than stock
I can mill the back side of the billet cover down .100" without an issue i'm sure.
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Do you anodize or have someone out there who does it? Can you machine a word on them? Like kawasaki, ect. ...
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I have a guy who does laser engraving for us, not sure what would be involved in making it have dimension and not just an etch like he normally does. I haven't worked with anyone to anodize parts but a friend in edmonton has had success with guys out there who can even hard anodize.
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Laser engraving would be cool. Probally easier too
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I checked in with my laser guy, he cant engrave the cover but can logo them with a laser impregnated film method of some kind. Not certain how that'd stand up to a boot scuff but at least its not going to make the covers any thinner. It can be done to anything except magnesium, meaning cast or billet aluminum in this case.
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I now have 2 covers that need this mod when they are ready
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Soon..... :-D
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Laser engraving would be cool. Probally easier too
I got a guy, will post pics when done.......
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Nice
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(http://i.imgur.com/e9nhy4H.jpg) got a gift from the north pole today :-D thanks roost
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Can't wait to see them done. 8-)
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welding these pieces, I've been able to have s junk main case handy so I bolted the clutch case to it, do what you can to clamp it on something flat. If the cover has had a previous ding in it then it'll be twisted to start with.
Don't try to clamp the ring down to the work bench etc. The heat from the welding will distort the case. If you need to hold it to get it tacked on then do it with a c-clamp or something that won't follow the case like a visegrip etc or it'll keep compressing until the case cools down.
I bake the case on a hotplate until I can tap out the governor bearing, not so that the bearing turns blue. The case should sweat out what oil it has absorbed and be much cleaner welding.
Start near the governor area, its the thinnest so do it before it gets too hot to work with. move counter clockwise so you end up at the heaviest portion of the case last.
should go smooth.
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Thanks for posting that info.
Mine turned out ok with not a lot of warpage but I made a steel ring to bolt it to.
I'll try your method next time and see how it works out.
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Yeah it is kinda low on my to do list atm. I have to rebuild the crank in both my motors before anything else and right now I'm just waiting on rebuild kits
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I need pictures :cry:
welding these pieces, I've been able to have s junk main case handy so I bolted the clutch case to it, do what you can to clamp it on something flat. If the cover has had a previous ding in it then it'll be twisted to start with.
Don't try to clamp the ring down to the work bench etc. The heat from the welding will distort the case. If you need to hold it to get it tacked on then do it with a c-clamp or something that won't follow the case like a visegrip etc or it'll keep compressing until the case cools down.
I bake the case on a hotplate until I can tap out the governor bearing, not so that the bearing turns blue. The case should sweat out what oil it has absorbed and be much cleaner welding.
Start near the governor area, its the thinnest so do it before it gets too hot to work with. move counter clockwise so you end up at the heaviest portion of the case last.
should go smooth.
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They're working out pretty well. We did 4 lastnight, changed the clamping procedure of things to zero. :roll:
The welder said he was getting 60-65 amps in it to puddle the pieces, only added minimal filler rod. The case finished flat, I did warp a mounting ear by .040" or so on 2 of the covers but installed them on a case half, warmed them and tapped them down with the brass hammer and they're perfect.
(https://8vrbew.dm2301.livefilestore.com/y2pZAn4LUlJv6njpHQTmhSEx_VeZDt8BbQ_PF1uajhIXd_n9ChwyJ54Wui0pR-w8vHmeZ-Xm_xU_PVMWxDDaYc_-kJN6hI2b9BJyQ8BGqCYAsA9XEB1QqmJiozObWhWPcPFrc871aEfOqSghRkWHRZpOw/20141212_164310683_iOS.jpg)
(https://8vrbew.dm2301.livefilestore.com/y2pJrb6lWgbx25pjayv8uB_tNFMk2kHgf0tERoi1ri6RhNXlB5wteEQkXMdQa_yaD_-YLarHeAEwEVKbk169Yc6AQPEH1LkjGq1ThIql19L-_9OJBUgaAnCLFHkM3tB-GSNh0WZJPyq4i0NEgFK5l6AYw/20141212_164302625_iOS.jpg)
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Nice job! :-o
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Those look great!
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So is anyone making these and selling them currently? I would really like to get one, would make tuning my auto clutch so much easier.
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Contact Roost at roostius_maximus@live.com
He can make you one with a deeper basket area to fit your auto clutch :-D
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one is done, now to powdercoat the outer cover and send out for engraving.
(http://i1240.photobucket.com/albums/gg485/alward25/97%20KX%20500%20build/photo3_zps68013080.jpg)
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Sweet!
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In case anyone has never seen the mythical Factory Kawasaki two piece clutch cover these are a couple pics I took of John Dowds factory Kx 500. You can see it was probably sand cast.
(http://rs1378.pbsrc.com/albums/ah95/chums179/Mobile%20Uploads/IMG_20150125_141224369_HDR_zpsca438307_1.jpg~320x480?t=1422383076)
(http://rs1378.pbsrc.com/albums/ah95/chums179/Mobile%20Uploads/IMG_20150125_141218043_HDR_zps35eb3ce4_1.jpg~320x480?t=1422383082)
Anyone wanna make me a trick piece like that! Lol its pretty cool!
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never heard of Jeff Dowd...did you mean John Dowd?...
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Yes. Was talking to Jeff Fredette right before on Ice tires, I'm getting old.
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Yes. Was talking to Jeff Fredette right before on Ice tires, I'm getting old.
eh...I was just bustin your balls more or less :-D...I knew who you were referring too.
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Ok dumb question, looking at alwards post / pic & chums post , I see a striking discrepancy.
Is there a way to keep the cut off portion & weld a ring to it as well so the sight glass remains intact