BannedCR500Riders.com

Was 'bout ready to install the carbon clutch, basket is notched pretty heavy.
I'm don't really want to drop the cost of a new hinson basket if I can help it.
recomendations on fileing the stocker.

PS,
sucks that the basket won't come out through the clutch cover

Grab a file and go to town, I used a 3" air grinder last time and it was done in under 5 mins.

Thanks, that's what I wanted to hear

Next question:
The Motor is an '01, when pulling out the clutch operating rod the the clutch lifter seperated, opps no ball, couldn't have gone far? can't find it, even pulled the case cover off and ran a magnet around, still nothing. checked out the parts list on bikebandit does'nt show one for that year, problem is, when I looked at the rod and at the lifter I can see little dents like it had one there? WTF.
I guess I'll measure the old stack of clutches vs. the new and see if it did or did not use the ball.
to be continued.....

Kuma wrote:Thanks, that's what I wanted to hear

I would go buy a new, sharp, equaling file and do it by hand.

Kuma wrote:Next question:
The Motor is an '01, ...checked out the parts list on bikebandit does'nt show one for that year.

[youtube][/youtube]

Bob,
you may get a kick out of this
First of all, would a brand new clutch operating rod and lifter be pre dimpled?
My bike is a service honda, '01, I bought it from a freind in '02, I know that he has not changed the parts and neither did I, so why is a bike bought as new got used parts in it?

I for one am not a service honda hater, I love my bike, most of the welds look good, if it were not for this bike I'd still be riding my '89 500. when I've called SH for help, they got on the phone and assisted me. 'nuf said, just a littls pissed that I spent several hours looking for a snipe

Kuma wrote:....so why is a bike bought as new got used parts in it?

I'll let AJ answer that one....

It's all good, I'm over it.
Besides, I think AJ is only watching one thread right now.
Very intertaining

I throw the basket in the lathe and make sure it fits, cleanup the flashing on the case too, I even cut down that brand new basket witht he stainless inserts on the fingers (best basket ever, super smooth, way better than the stock style witha magura)

Roostius_Maximus wrote:I throw the basket in the lathe and make sure it fits, cleanup the flashing on the case too, I even cut down that brand new basket witht he stainless inserts on the fingers (best basket ever, super smooth, way better than the stock style witha magura)

I just cleaned up the stock one, and put it back together, I only need to get in there every 2 -3 years. next time I'll buy a new basket before I even crack it open

Roostius_Maximus wrote:I throw the basket in the lathe and make sure it fits, cleanup the flashing on the case too, I even cut down that brand new basket witht he stainless inserts on the fingers (best basket ever, super smooth, way better than the stock style witha magura)

Who makes a 500 basket with the stainless insert. The 500 does not show up on the barnett site.

http://www.barnettclutches.com/products ... make=Honda

maddog, I believe it's Siezeco that makes it. I've seen pictures of it. I'm not 100% sure , but that's my guess.
My bad. I just checked their website and didn't see it. Fuck, I can't remember who makes it. Wanted to buy one myself a while ago. The mfg escapes me. Roosty will know in the morning.

i use 2002+ cr 250 / crf 450 clutch parts and the 2002-2003 shifter components except forks and fork shafts.

Really does filing the notches off the fingers really work?

for a bit, but its not the right way to fix it

As soon as ther is one finger applying more load from not being filed as much as the others you've made a spot to weaken the clutch fiber and will likely break it. It's all a mess from there

DonDDR wrote:Really does filing the notches off the fingers really work?

*might* only if you go slow on the filing, only taking the high spots off and STOP when you get to the lows.

All in all just get a new basket

only taking the high spots off and STOP when you get to the lows

i stop a bit before i get to the lows, that way the basket still aplyes even pressure to the plates

Roostius_Maximus wrote:As soon as ther is one finger applying more load from not being filed as much as the others you've made a spot to weaken the clutch fiber and will likely break it. It's all a mess from there

Exactly what I thought.

This was in my donor motor, has since been replaced with a hinson.

I'm truly surprised the fibre plates hadnt broken, the tabs were mashed up and shortened 2-3mm easily.

if the new basket got used fibers its just as bad.
btw, the KTM 250+450 from 07+ use the same inner hub , fibers and pressure plate as the honda 250/450

new basket definetly got a new clutch pack installed!

funny thing was the pressure plate and inner hub was like new... did pull the inner hub out and add additional oil holes while it was all apart, also replaced the collar and bearing the basket rides on as it had a weirdly large amount of play.

dammn

Ugly ehh?!

This motor also had a 2inch crack up the backside of what I think may have been the original piston.

Luckily I never ran it before a tear down!

I had a fibre break in my 01 250 during a harescramble a few years back, the clutch made a hell of a rattle when I was slipping it, but I was leading the class, and my biggest competition had siezed his bike earlier in the race. It lasted an hour of racing, with two broken fibres staying in place.

Needed a new basket, hub and ppressure plate but it was likely due for them anyways.