87 upgrade to 250 clutch?
Posted: February 22nd, 2014, 2:06 pm
I already posted a thread about an issue with my clutch dragging, but have decided to skip tracking down the problem, and just replace everything. This is because I don't trust the person who put this thing together before I bought it. That, and I don't feel like fixing one problem, only to find another one. The one good thing the previous owner did was replacing the clutch case with the 90-01 case. So that's one major part of this upgrade I don't have to worry about. What follows are diagrams, followed by a list of the parts with numbers corresponding to that pic, then part number, name, and price (with quantity when more than one is necessary). What I need is for someone who knows what parts are required for this conversion to either confirm, or correct this list. I also need to know specific details for modifying the clutch basket, and lifter rod length. The machinist where I work will make the required changes, but not without a schematic. I just need to know where to take off how much metal in thousandths of an inch, so I can draw one up for him.
1987 CR500R OEM replacement
K28-5502
Clutch Cable
$12.95
Is there a "best" cable that has been found to last longer, or perform better? Is 13 bucks a decent price? Any suggestions?
1990 CR500R OEM replacement
6
22810-ML3-000
LIFTER, CLUTCH
$41.30
17
91201-951-003
OIL SEAL (12X18X3)
$2.13
15
91101-PZ9-000
BEARING (12X16X10)
$4.62 X2
1990 CR500R OEM replacement
12
22851-HA2-670
ROD, CLUTCH LIFTER
$11.17
If this part has to be modified, how much has to be taken off in thousandths of an inch?
2002 CR250R OEM replacement
15
90022-MM5-000
BOLT-WASHER (6X25)
$1.73 X6
Are these the correct bolts, or should I be using 500 parts here (part 22 in the 1990 clutch diagram)?
1
13115-147-000
CLIP (10MM)
$1.21
21
90608-072-000
WASHER (12MM)
$2.27
22
91001-147-003
BEARING (12MM)
$6.60
11
22352-ML3-910
PIECE, CLUTCH LIFTER
$17.63
16
90235-KA4-000
NUT (18MM)
$5.51
19
90461-KZ3-J10
WASHER, LOCK (18MM)
$3.54
20
90501-ML3-910
WASHER (18X32X2)
$2.53
18
90421-HA2-010
WASHER (23X48)
$5.47
23
91021-ML3-003
BEARING (28X32X27.2)
$9.35
5
22106-KS7-000
COLR, CLUTCH (OUTER)
$13.79
2002 CR250R aftermarket replacement
(credit 2strokeforever 5/25/12)
1131-0151
Barnett
Billet Clutch Basket
$201.00
Is this the correct basket? It is the only one I could find that fit the description of having stainless steel inserts where it contacts the friction plates.
1132-0227
Wiseco
Inner Clutch Hub
$249.98
Correct for this upgrade? I guess this brand warranties their product for life.
HPK-80DCF
Barnett
Complete Dirt Digger Clutch Kit - Carbon Fiber
$156.37
Will the new EBC springs I already have for the 87 500 work with the modern 250 clutch? If so, is there somewhere I can buy just the friction disks, and steel plates?
1132-0412
Barnett
Billet Pressure Plate
$140.70
The photo on partzilla isn't the same as above, but it's all they have for the 02 cr250. Could it just be a stock photo?
I really REALLY need some help with all this! Thanks a million for any contribution, I'll owe you a drink!
P.S. sorry for the long list.
1987 CR500R OEM replacement
K28-5502
Clutch Cable
$12.95
Is there a "best" cable that has been found to last longer, or perform better? Is 13 bucks a decent price? Any suggestions?
1990 CR500R OEM replacement
6
22810-ML3-000
LIFTER, CLUTCH
$41.30
17
91201-951-003
OIL SEAL (12X18X3)
$2.13
15
91101-PZ9-000
BEARING (12X16X10)
$4.62 X2
1990 CR500R OEM replacement
12
22851-HA2-670
ROD, CLUTCH LIFTER
$11.17
If this part has to be modified, how much has to be taken off in thousandths of an inch?
2002 CR250R OEM replacement
15
90022-MM5-000
BOLT-WASHER (6X25)
$1.73 X6
Are these the correct bolts, or should I be using 500 parts here (part 22 in the 1990 clutch diagram)?
1
13115-147-000
CLIP (10MM)
$1.21
21
90608-072-000
WASHER (12MM)
$2.27
22
91001-147-003
BEARING (12MM)
$6.60
11
22352-ML3-910
PIECE, CLUTCH LIFTER
$17.63
16
90235-KA4-000
NUT (18MM)
$5.51
19
90461-KZ3-J10
WASHER, LOCK (18MM)
$3.54
20
90501-ML3-910
WASHER (18X32X2)
$2.53
18
90421-HA2-010
WASHER (23X48)
$5.47
23
91021-ML3-003
BEARING (28X32X27.2)
$9.35
5
22106-KS7-000
COLR, CLUTCH (OUTER)
$13.79
2002 CR250R aftermarket replacement
(credit 2strokeforever 5/25/12)
1131-0151
Barnett
Billet Clutch Basket
$201.00
Is this the correct basket? It is the only one I could find that fit the description of having stainless steel inserts where it contacts the friction plates.
1132-0227
Wiseco
Inner Clutch Hub
$249.98
Correct for this upgrade? I guess this brand warranties their product for life.
HPK-80DCF
Barnett
Complete Dirt Digger Clutch Kit - Carbon Fiber
$156.37
Will the new EBC springs I already have for the 87 500 work with the modern 250 clutch? If so, is there somewhere I can buy just the friction disks, and steel plates?
1132-0412
Barnett
Billet Pressure Plate
$140.70
The photo on partzilla isn't the same as above, but it's all they have for the 02 cr250. Could it just be a stock photo?
I really REALLY need some help with all this! Thanks a million for any contribution, I'll owe you a drink!
P.S. sorry for the long list.