Replacing oem clutch basket question

[mtsnieg]

I ordered a new Wiseco clutch basket for my '85 250r to replace my haggard oem one. What is involved in changing over the gear? New basket comes with the bolts to bolt it on. Is the oem basket bolted to the gear? I don't have it off the bike yet. Just want to be sure I don't run into any suprizes, Gonna do the swap Saturday morning so I can ride later in the day. Thanks, Matt.

[SWIGIN]

You need to grind off the factory rivets to remove the gear. Then bolt it onto the new basket.

[Mosh]

This is the easiest method for me using crude tools that most guys have in a typical garage.

http://www.3wheelerworld.com/showthread.php/91712-Tri-Z-Billet-Clutch-Basket-Installation-Thread

OH YEAH...Let me warn you. Most of the time on the 250R, especially the 85 and some 86's engines, the new basket is so thick it will rub on the primary gear of the crank. You will have to remove the primary crank gear and shave or bevel the gear back so it does not grind on the new aftermarket clutch basket.

Here is a link to the fiasco.

http://www.3wheelerworld.com/showthread.php/94868-250r-clutch?highlight=basket

[mtsnieg]

Thanks for the info Mosh, it's just what I was looking for. Good heads up on the primary gear. I'll post some pics this weekend when I get it done.

[Mosh]

No prob..I wish I had the info at my fingertips back in the days, instead of trial and error..But that is how we learn..Good luck!

[deathman53]

the hinson one came with instructions, grind the end of the rivits on the backing plate, pry off the backing plate, remove gear, remove rubber dampeners on the basket, if your dampeners are broken or in 2 peices, crf450r dampeners are identical(and available from hinson). put basket in oven or something at ~200 degrees, put splined shaft in freezer. Hold hot basket and slide(or gently hit) splined shaft it, its a tight fit, when everything is cool, put dampeners on basket, gear on basket, put on backing plate, clean threads of basket and bolts with brake or carb cleaner. Put red loctite on threads of both, put all bolts in and tighten all to ~10 f/lb, basically screwdriver tight and give it an extra 1/2-3/4 turn. Put basket on bench(gear side on bench) and use a punch and hammer to hit the bolts in the basket, this will peen(distort) the end of the bolts so it will be very unlikely loosen. This is basically what the instructions for the crf450r basket and 250r basket from hinson said. The hinson one did say beveling of the primary gear(bolted to crank) might be needed, as it will rub on the basket on 86 motors(85 motors are really really close).

[mtsnieg]

I got the gear and rubber isolaters off last nite. Piece of cake with a die grinder and carbide bur. Got off work early today, now I'm lookin out the window every couple a minutes like a crack-head, waiting for the UPS guy with my new basket. Couple a pics of the old haggard basket.

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[ChrisD]

If you have a die grinder, that is perfect. I attached my gear to the end of the wizzer wheel and center it, then, at a 45 degree angle, I ground it on my bench grinder. With the gear spinning at whatever thousand RPM and the bench grinder spinning, I came up with a perfectly balanced grind. If you PM me your email, I will send pics. For some reason, I cannot post pics from my I phone.

[mtsnieg]

Installation went smooth. The Wiseco kit came with great instructions, and a new backing plate. The instructions said beveling of the primary gear may be neccessary. It was so close. It didn't seem to rub, but I beveled it a bit anyways. No more chatter, and it really seems smooth, but I already have done the '89trx upgrade.

[ChrisD]

Be glad you did bevel it. It doesn't touch when you look at it, but it does when the basket flexes under strain. I'm glad it went well. I have done 2 of them now and it's a great improvement.