KX Riders
Maintenance & Technical => KX500 Original => Topic started by: ebers17 on July 25, 2005, 02:29:34 PM
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Anybody modify a clutch cover within the clutch cover? Instead of draining the coolant and taking of the kick stand and etc. everytime you change a clutch, you only need to take off a cover over the clutch? I talked to a guy at a local shop who actually raced 500's in the 90's professionaly, and he said thats what they used to do b/c they changed it so much. I never did ask him how they did it, and hes not around anymore, so i was wondering if anyone out here has ever done it. I'm thinking mostly alot of machining on the cover.
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Anybody modify a clutch cover within the clutch cover? Instead of draining the coolant and taking of the kick stand and etc. everytime you change a clutch, you only need to take off a cover over the clutch? I talked to a guy at a local shop who actually raced 500's in the 90's professionaly, and he said thats what they used to do b/c they changed it so much. I never did ask him how they did it, and hes not around anymore, so i was wondering if anyone out here has ever done it. I'm thinking mostly alot of machining on the cover.
I was thinking about doing it a while ago, by getting a secondhand cover and getting it machined then with a bit of luck (if the sizes were about right) using the removable cover from a 250 cos at least then the gaskets would be easy to source instead of having to make them up.
Never got round to it though as with spending huge sums of money on the house I am kind of skint nowadays :(
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Theres a good picture floating around here of one that was done for a auto clutch.Dig a little,its here somewhere.
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Has anybody done one of these modifications? It's been a while since I've last asked and a while since I've really thought about doing this, but after seeing the af's being done, I'd like to do that with a modified clutch cover too. I'm thinking of ways to do it, but just wanted to know if anyone else has done it with any luck?
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I have seen pics of those on the old factory KX500's. Pretty nice. I don't change my clutch often enough to ened one. Maybe the drag strip boys need it! I recall last I had the cover off for a fast fix at a race I was able to put the bike on it's side and flex the cover out of the way without draining oil or coolant. A foggy memory- possibly not entirely correct. Cam.
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You would'nt happen to have any pics of those factory 500's with that mod shown would you? I've looked around on the web and can't find anything?
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This is the only picture I have seen. Looks to have custom made cover. Team Green Bike in the photo.
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Nice pic, that is sweet for sure. I think I might need to do something like that for the bling factor. Thanks for the pic!
Sly
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That is exactly what I was looking for! It looks like that cover was all machined with that in mind. I don't know exactly what I'll do, but I'm going to put some thinking into it. That is one sweet looking machine right there though, I wish mine was that clean!
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Where did you find that picture by the way? I'd love to see more of that bike! Thanks by the way!
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That's the one only Destry Abbott's Team bike. I grabed that photo off of his web-site under his formun.
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Other side
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That removable clutch cover is SWEET! I like that and the protector bar in front of the water pump. If anyone finds a place to buy that clutch cover pass on the information.
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Notice the Varner sticker on the cylinder?
And the writing on the side of the carb float bowl?
(http://www.kxriders.com/forums/index.php?action=dlattach;topic=1615.0;attach=759;image)
I am pretty sure thats who does the cylinder tuning for his bike, has anyone here had tuning work done by Varner?
And by the looks of it that particular day he was running a 168 mainjet, a N89D-3 needle? and a 55 pilot jet
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I'm pretty sure thats a custom peice, I'm going to look into it, I've got a couple ideas.
Hows he keep everything so clean too!!!!!!??
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There's a stator protector loop too ! And notice the billet clutch arm. And I notice he puts the clutch cable "outside" the frame, like I learned to do from this forum.
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I'm pretty sure thats a custom peice, I'm going to look into it, I've got a couple ideas.
Hows he keep everything so clean too!!!!!!??
Pro riders have techs that completely disassembly their bikes after each race to clean, lube, replace anything that it needs. Just think Destry rides in the desert at a high rate of hurry and I'm sure his bikes need major cleaning and lubing or repair after each event.
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That is a great picture showing the front exhaust pipe mount. If you look at the anti-vibe rubber bracket you can see how bad the FMF pipe brackets are mis-aligned causing excessive tearing forces on the rubber. Just take a large crescent wrench and twist the pipe bracket more parallel with the frame tab and you will increase the lifespan of the anti-vibe bracket considerably.
Sly
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That removable clutch cover is SWEET! I like that and the protector bar in front of the water pump. If anyone finds a place to buy that clutch cover pass on the information.
Contact Kawasaki's racing division and have your AMA Pro factory rider resume ready. That clutch cover is an "unobtanium" magnesuim works piece. Notice the added threaded bosses to accept the screws? There is no way to mod a production KX500 cover to work like that works unit. Ahh the trickery of the works bikes. I went to a Parts Unlimited AMA pro track day at Southwick, and I even got a chance to ride Pastrana's factory 125 practice bike. All's I can say is oh my god....... The shear screaming power, and the suspension felt like you were floating on a cloud.....
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You can go my way if you want! :evil:
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The whole bike. :evil:
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How did you do it!?
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Man that looks cool, and yes how did you do that?
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Easy! :-D
Shave of stock clutch-cover and make a aluminium ring 10mm thick and then weld it on. :wink:
Drill some holes (approx 4mm) and add a gasket,done! 8-)
Now the clutch is working almost as I want it,just some more spring preload at perchadjustern and then race test for a day or so. :evil:
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Thats one hell of a bike there doordie.
Check out the clutch arm on Destry's bike.... where do I get one of those? I imagine it is probably longer than stock already? Let me guess... unobtainable? Sweet looking none the less. I shouldve been a machinist so I would know how to make my own parts like those.
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I have a lot of questions for you doordie, when will it all be ready for production?
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Thx for your positive words guys!
Hangtime,when I have everything ready and tested you will the first to know! :wink:
(But email me your questions if you want)
You have my serious respect with your K5-AF! :evil:
Rekluse have been very helpful to this project,even if they will not fabricate a kit for KX500.
But with ordinary tech.knowledge (and not the tumb inside your palm :-D) you can do it by yourself with my "help". 8-)
My iceroad season is comming up now and short of time as usually! :x
I says as Arnold S:
I`ll be back :lol:
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...I recall last I had the cover off for a fast fix at a race I was able to put the bike on it's side and flex the cover out of the way without draining oil or coolant. A foggy memory- possibly not entirely correct. Cam.
that is how i chang most clutchesd
~steve
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i think i know where to get a clutch arm like that one. let me do some checking around.
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Stupid question maybe :? :? :? :?
Will a (older)250 clutch cover/carter fit on a kx500 :? :?
Dutchie
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Stupid question maybe :? :? :? :?
Will a (older)250 clutch cover/carter fit on a kx500 :? :?
Dutchie
I have an 89 KX250 inner clutch cover that "supposedly" is a direct bolt on for the 500. I'll pull my 500 out one of these days and try it out.
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I to was told that the 89 would work, I'm not sure. The water outlet is different than the K5.
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i'm working on some thing too. have picture posted soon.
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Did any one had any luck with a clutchcover :? :? :? :?
Dutchie
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i'm working on it, but also working on other goody for this motor. :-D
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i'm working on it, but also working on other goody for this motor. :-D
Any luck Kaw Rider :? :? :?
Dutch
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I will soon be in need of replacing the clutch cover on the '89 KX500 engine I just picked up also. Looks like he went down and put a hole in it, then welded in back up (or JB weld I don't know)
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So did anybody find out if the 89 250 engine inner cover will bolt on?
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Different part # on gaskets.
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plus i think the basket is bigger in diameter.
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I've also searched about this. The gaskets are different, espacially at the pin # 92034 and the front.
Maybe it could work, only it doesn't look by this.
Maybe Hillclimber can tell us???!!
Dutchie
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I had to search a while for this topic. The 89 KX250 clutch/case cover does not work. Not even close.
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That removable clutch cover is SWEET! I like that and the protector bar in front of the water pump. If anyone finds a place to buy that clutch cover pass on the information.
SWEET STUFF THERE!!
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I had to search a while for this topic. The 89 KX250 clutch/case cover does not work. Not even close.
Thanks for replaying Hillclimber! I know it's almost a year ago, Still thanks!!!! :mrgreen:
This was what I've discoverd. A cover from a 92 kx250.
http://www.kxriders.com/forums/index.php/topic,6792.15.html (http://www.kxriders.com/forums/index.php/topic,6792.15.html)
Dutchie
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communication error....
does the 92 cover fit the 500?
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It looks the same as the SR cover. So it could fit :?
Don't know how much modifycation it needs.
Dutch
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Doug
Here are the pictures
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i have some outer clutch covers from various bikes, and have about 6 500 side covers for my 3 bikes. i was going to make a 2 peice job when i built my 86, but just trying to weld the crack i had was a mother. the old kawasaki aluminum parts seem to be made from junky metal. when you wled on it it is like it was covered in crud and you just started burning away, but my part was spotless, mek'd the whole deal. i had to fix a bunch of stuff on my 86 cases, half the clutch actuator was gone, and lower chain guard tab gone. the metal there was not too bad. but my clutch cover was a pain.
i have some 90s era covers, one is pretty trashed, so not too worried if i kill it. was thinking i might give it a go soon. i have never liked taking the whole side off to mess with the clutch. it looks like the later aluminum wasn't so terrible.
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Anyone know how to get your hands on that splined clutch actuator rod with the nice billet pull arm on it? That thing is sweet! mine just a welded tab piece of junk! And in that second pic, what is that sensor or switch he has the arm activating? is that an engine cut? DEF. TRICK!! 8-) 8-) 8-) WAIT a minute, that second pic is of a four stroke, isint it?? I WANT THAT CLUTCH SET UP!
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The second engine is a four stroke,. I've been wondering about the switch myself.
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You would like this aluminum clutch arm here, I will be having it tested this spring then i will release it after testing is done.
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:lol: :lol: :-D :-D :-o :-o :-o :-o AWSOME AWSOME AWSOME :-o :-o :-D :-D :-D
KAW RIDER DEF KNOWS HIS S#*T
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Read some of his articles and you'll understand why I agree.
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X2 on Kawrider
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Man, someone should start bangin' these covers out! I bet if you did there would be a sizeable market for it. :wink:
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I think most people would pass on it when they see the cost of it. What would you pay for one.
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how much is it? just curious
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I still wonder why.... Bling factor is cool.. But its a 500... how often do you guys replace clutches?!
My 1987 still has the original clutch in it.. and it has ALOT OF MILES ON IT... is an understatment..
Sure.. desert race is pretty darn easy on clutch. (use it when shifting and starting stopping)... no hammering on it.. but still... its a 500.. no need to clutch it like a 250 125...
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The auto clutch guys would like it.
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The auto clutch guys would like it.
True. forgot about them...
I also think Im one of those people that are easy on clutch's.... I have never had to put a clutch in any of my stuff... (after rebuild due to previous owners...)... even in my little bikes.. (175, 250 etc)
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When I bought my KX500 from Team Green, I was disappointed that my bike did not have the clutch cover mod. I raced desert for years on KX80s, KX125s, and KX250s and never replaced a clutch on any of my bikes (probably because I was using the recommended 10w-30 oil!). This is my first 500, so I wasn't sure if it would be different from my other bikes. Well, I bought the bike used and have put about 30 gallons of fuel through it, and it hasn't missed a beat.
One thing that I have noticed though is that my oil gets dirty almost instantly. I change it every ride, and it's always dark. None of my other bikes ever did this, but they were mostly stock. I think this bike has a Hinson basket and steel clutches, but does anyone else have this issue?
I put a photo of my bike that I took last weekend at El Mirage Dry Lake. She is now ready to desert race!
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When I bought my KX500 from Team Green, I was disappointed that my bike did not have the clutch cover mod. I raced desert for years on KX80s, KX125s, and KX250s and never replaced a clutch on any of my bikes (probably because I was using the recommended 10w-30 oil!). This is my first 500, so I wasn't sure if it would be different from my other bikes. Well, I bought the bike used and have put about 30 gallons of fuel through it, and it hasn't missed a beat.
One thing that I have noticed though is that my oil gets dirty almost instantly. I change it every ride, and it's always dark. None of my other bikes ever did this, but they were mostly stock. I think this bike has a Hinson basket and steel clutches, but does anyone else have this issue?
I put a photo of my bike that I took last weekend at El Mirage Dry Lake. She is now ready to desert race!
Only time I had that issue was when running alum clutch plates...
swap to steel.. and problem goes away...
where do you desert race? I race D38... I asume your D37?
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I raced D37 for years, but I took a break from racing when I went away to college and to get my career going. When I saw a real Team Green KX500 for sale, it was just the inspiration I needed to get back into it. I haven't raced the bike yet, but I'm trying to put some hours on her to get used to it. I can't wait to do my first bomb run on the KX500!! Now if I eat dust on the bomb, it will be due to my lack of courage to hold the bike wide open for a prolonged period, not because my bike is topped out at 85mph like my old 250.
The KX500 was dominating the desert when I got out of racing and continued to do so until 2005 (they raced the 2004 KX500 in 2005 since the 450 wasn't ready to race yet). Instead of buying a new KX450, I thought I would reintroduce myself to desert racing on the most tried and true desert machine ever. Not to mention, nothing like going riding with all of your buddies who refer to your bike as "A man's bike". It's the only bike I've owned that people are afraid to take for a spin!
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I raced D37 for years, but I took a break from racing when I went away to college and to get my career going. When I saw a real Team Green KX500 for sale, it was just the inspiration I needed to get back into it. I haven't raced the bike yet, but I'm trying to put some hours on her to get used to it. I can't wait to do my first bomb run on the KX500!! Now if I eat dust on the bomb, it will be due to my lack of courage to hold the bike wide open for a prolonged period, not because my bike is topped out at 85mph like my old 250.
The KX500 was dominating the desert when I got out of racing and continued to do so until 2005 (they raced the 2004 KX500 in 2005 since the 450 wasn't ready to race yet). Instead of buying a new KX450, I thought I would reintroduce myself to desert racing on the most tried and true desert machine ever. Not to mention, nothing like going riding with all of your buddies who refer to your bike as "A man's bike". It's the only bike I've owned that people are afraid to take for a spin!
Well. when my motor is back together. (within the next month).... we will have to get together and run a D38 or D37 race... As my bike is a EX-Team green bike also... Can be a Ex-team green party or somthing... Make sure destry is there.. so I can pass him in a straight away to remind him what he is missing out on now...
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We should team up and do a race Motorrad, that would be a lot of fun. I've been watching your posts on your Ex-Team Green bike, and you've got a really nice machine that I'm sure all of your hard work and attention to detail will pay off. I haven't done anything to my motor yet except for doing a leakdown test when I first got it, and based on the test there didn't appear to be any problems. I like gathering data and seeing other builds to get ideas for when I do rebuild the bike.
And I'm sure there are times when Destry misses the mighty KX500 power, as I've seen posts where he discusses how the KX500 has the advantage on the KXF450 on 70mph and above. I'm sure the reason for the 70mph and above figure has a lot to do with traction, but I used to watch bomb runs where the KX500s in the hands of the pros would put a woopin' on all of the other bikes, and I never saw any of the pros have problems starting the bike at the drop of the flag like I've seen with the 4-strokes.
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I think most people would pass on it when they see the cost of it. What would you pay for one.
I paid something like $300 for a 2 piece cover for my 2005 KTM RFS when SFB was making them from billet, so something in the $300-375 wouldn't be unreasonable. Perhaps a billet inner cover to use an off the shelf KX250 etc. removable clutch cover to reduce costs?
Maybe just a machined stock one with a laser welded billet adaptor plate to mount a stock KX250 cover???
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i am still wanting to do this to my 86, i have found a few various year older kx250 side cover/ outer covers that i'll have soon. i wonder if those team green bikes had modified oem covers or totally new made ones from japan?
i envy you desert racer guys. i always wanted to do that, but where i live it just isn't so.
motorad i want an easy access cover just because for whatever reason i have a problem with kawasakis and clutch dragging. i have owned many kxs over my life, but have always had something needed on the clutch stuff. my last kawi build was a 86 500, everything clutch oriented is brand new, and still here i am with a small issue of it dragging.
maybe i am just lazy and don't feel like doing everything needed to remove it currently. if i had this outer cover it would be a few minute ordeal to sort out. wouldn't need to even drain any fluid, just lay on side.
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I was going to make one using a kx450 outer cover. Very common gasket and you can get some cool covers. I am also going to make some outer covers too that could be personalized. After my move in about 2 months. I will keep you posted.
Alex
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they should have put the removable outer clutch cover on the kx500 like they did to the kx250 in 88 :?