[QUOTE=Daddio;626495]On the second race of the year 1upfronts 300r smoked the clutch in a bad way. He said that he wouldn't put it back together until he could find something more durable than the stock set-up. Well after much research we decided that no one makes anything for the air cooled Rs. So he said that he thought that the 78-80 cr 250 shared the same clutch as the 81-84 R. I looked into the prospect of finding out what was available for these. I was able to find a billet clutch basket for the cr 250 on ebay uk. It was quite pricey and took a while to get this guy to ship it to the states.
The next problem was the play where the kick start gear fits into the clutch drive gear. This is important because the clutch bearings fit inside of the kick start gear and the gear actually supports the drive gear and basket. We thought that welding the two together would solve this problem. The drive gear is cast so that limits what you can do as far as welding. So after much discussion with many people we decided to braze the two together. That went pretty well. After brazing we put it in the oven and let it cool down over a period of several hours.
The next problem was that the center of the gear that rides on the bearing had shrunk about five thousandths of an inch and it no longer fit on the bearing. We took it over to a good friend of mine, who is the local Harley guru and millwright, and he honed it back to stock specs.
Now we are ready to join the new basket to the modified drive gear. The new basket came with solid rivet for this task. This would be easy with a rivet press but I don't have one so we had to do it the hard way. The old and bucking bar method.
This new basket uses 300ex clutch plates and the stock hub and steel plates. He bought some cr500 clutch springs for it and as soon as the new steels get here it will be going back together for a trial run then weather permitting we will be taking it to Dirt Country on the 7th for a TF warm up.
I'm not clear what needed to be done to the rivets. Can you explain?
3 CR500R's and counting. Do I really need 4???
Do I really need 9 Tigers?
Laegers ATC500R
DO NOT send any thing to whats his face (dirt-face/crasher) here on the board. What a scum bag. He screwed (stole) money from me and screwed me on my ME360 and Hondaline 300R engine rebuilds.