Originally Posted by dgowland
Check the fingers on the basket and grooves on the hub for notches . You can file them smooth again and likely fix your problem . The hub isnt too expensive if its rough ...
People do this with dirtbikes fairly often. Dirtbikes seem to have more of a problem with this than other bikes, from what it seems (I dont hear about this with streetbikes much).
I have a KX500, it had a badly notched basket. spent some time filing out the notches, trying to make the basket work (it had bad clutch drag, didn't want to fully release). Took longer to do than you'd think (since you have to file each tab individually. Even with a nice fairly new big bastard file it took a while.
Doesn't last very well though, the basket is still just as soft as it was before, and now the slot the plates fit into is wider, and I'm not sure if that just makes it wear out even faster, by giving the plates more room to bang back and forth (conjecture on my part)
Anyways, it only took about 5 hours more riding (I did some mods to the motor, replaced the main bearings, but they went bad again b/c of a bad crank so I had to tear it down again) and the basket was starting to notch again!!!
I said fuck it and just put in an aftermarket heavy duty (high quality aluminum, anodized) Hinson outer clutch basket (about $200). Also replaced the inner basket w/ a heavy duty one just for good measure (was about $85, was tired of tearing this motor down and fixing things!!!)
I've got a K4, 6500 miles on it (1200 from me), the prior owner ran it fairly hard but was VERY good about maintenance and parts replacement, and the clutch is pretty grabby
I think i'll end up doing something with the clutch. Either a new basket (another hinson probably, about $350 discounted), though I hear Schnitz racing has a clutch mod that is supposed to work pretty well, about $150 or so. Either way, while I'm in there, I'll probably replace the friction plates (stock suzuki OEM is very good i hear), deglaze the steel plates, and go with heavy duty springs (on my 1K1 I replaced 3 of the springs with HD, not all 5, this is an "approved" or "suggested" Schnitz mod for street 1000's....)
I'm running a fairly stock motor, and I dont dragrace, so the clutch isn't going to get that much hard loading, so the stock basket should hold up....