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My clutch basket has some deep grooves in it, a good millimeter or more. I think the basket is beyond filing, but I don't know for sure so I'm looking for opinions. Is it worth salvaging? If it is toast, is there anywhere else to get a basket besides Fredette or OEM?

Also, on the hub nut, I searched and have some ideas for holding the basket while loosening the nut, but what's the best way?

Finally, is applying increasing torque (with a pipe on a breaker bar if needed) the way to go to loosen the hub nut, or is hitting the breaker with a hammer the better idea to break it loose?

I have posted this before but I own a Kawaski Concours street bike and there is a great forum for that bike. You can learn anything and everyting about the Concours there. I never expected to find the same thing when I bought my KDX but I think I have. Y'all rock and I appreciate the help while I am learning my way around the KDX. Thanks!

Hit the nut with an impact wrench, or do the penny trick in the gears.

Impact wrench. Takes about 5 seconds with the cheap electric Harbor Freight one I have.

I don't know of anyone other than Fredette and OEM. Sorry.

SS109 wrote:Impact wrench. Takes about 5 seconds with the cheap electric Harbor Freight one I have.

I don't know of anyone other than Fredette and OEM. Sorry.

+1

If it was me I'd file it

Actually I'd use my Dremel

You can remove the plates, and file it in posistion if need be. Just shove some rags in the case to catch the shavings. It will take more time though, and you have to be real carefull that the shavings dont go in the case. Add new oil when done, ride it for a few minutes. Change the oil again. Check for metal in the oil. Should be good to go.

I'D file that basket without hesitation.

I would pull that pushrod in the center of the clutch and make sure you have the shim that goes under it if there is one. Put 'em away safely, they are easily lost in the shuffle.

I've been using XR400 friction plates.

I have filed plenty of baskets in my day, and that is a good candidate for that practice - however, you should be aware that filing the basket will accelerate the wear at that spot, and the basket will soon be gooved again - much quicker than those originally appeared. I suspect this is because the plates have more room to slap back and forth...

gregp wrote:I have filed plenty of baskets in my day, and that is a good candidate for that practice - however, you should be aware that filing the basket will accelerate the wear at that spot, and the basket will soon be gooved again - much quicker than those originally appeared. I suspect this is because the plates have more room to slap back and forth...

Hmm ... makes sense. How soon is soon? I'd rather stay out of there for a while once it's done.

Is the FRP basket any more durable than the stocker?

Any deeper than .020" and it needs replaced in my opinion.

I'd replace that basket.

The FRP basket is more durable. I don't think it would ever groove.

Mine was grooved like that back in '03

I carefully removed the largest grooves with my dremel then filed it square

It still looks great today

Mr. Wibbens wrote:Mine was grooved like that back in '03

I carefully removed the largest grooves with my dremel then filed it square

It still looks great today

I know you LOVE to reuse old parts, but cmon that's just ridiculous....

Slick_Nick wrote:
I know you LOVE to reuse old parts, but cmon that's just ridiculous....

LOL I knew that was coming...

I don't see the point in trashing something that could still give you another year of use (maybe more, maybe less).
What do you have to lose? it shouldn't take too long to remove the clutch, file that smooth and go ride.
There is an article on thumpertalk about filing the clutch basket in the how to section.
I'd get the new basket as a back up when money is available, but that's just me.

Slick_Nick wrote:

I know you LOVE to reuse old parts, but cmon that's just ridiculous....

Aren't you the one polishing rusty old bearings...

it's nothing compared to your krusty old bearings

Mr. Wibbens wrote:it's nothing compared to your krusty old bearings

Krusty is the new clean! I was just ahead of the trend! ;)

Possibly stupid question but I need to ask so I can learn.

Where is the damage I'm looking for here? Is is the four grooves in the basket where the plate tabs have carved themselves in?

What problem does this cause? Plates do not seperate easily?

Your solution is to file these grooves away. Does this make the opening bigger allowing for slop in the plates?

Thanks!