125-200cc 96 CR 125 Clutch Basket Movement

Hi all,

In the process of tarting up the CR125 I bought.

Have removed the clutch and found the basket has a lot axial movement. It seems to be caused by the thick thrust washer between the basket and drive plate.

Can anyone confirm if this is normal? Looking at the part manual, all the bits are there. If you remove the thrust washer, movement is gone, but that mean inevitable contact between the basket and drive plate.

Trying to put a video on YouTube, my connection doesn't look like uploading to YouTube at the minute!

Your basket is pretty notched up also

try Halls for a new basket and rivets to connect that to the base disk and simply be done with it

Robert-Jan

But the movement will still be there if I just replace the basket, right?

The whole basket on my 360 moves about 1mm ist if you wibble the entire lot, new bearings didnt solve the issue i assume it is a built in tolerance.
As for the inner basket wobbling not checked, your basket is toast i think, try talon if your in the uk.

There is a gear on the inside of the basket which meshes with the kick start idler gear. Is the gear inside the basket supposed to be fixed inside the clutch basket or should you be able to remove it?

Mine slides straight off.....

Its got rubber bushes called cush drive it takes the hit out of suddenly slamming it into first.
If thats moving new bushes are required and strip clutch basket to do it, better off getting new bushes n basket.
Kick start idler is wafty at best so dont worry bout that.

I'll get a picture to show. I did a video of striping it down which shows exactly where the movement comes from. But having trouble uploading.

I think the bushes are between the alloy basket part and the iron (?) ring gear driven by the crank. To do the same job as the springs on a car clutch drive plate.

Things like this are hard to explain with words......so many terminologies for single components!haha

that is the worst basket i have seen fwiw

Looking at other baskets for sale and parts manual, the removed gear shouldn't be able to be removed.

It is pretty worn, probably beyond filing.

Any ideas what bikes/engines my bike shares one with. Can't justify buying a brand new one considering how much I paid for the bike! There are plenty of husky baskets on eBay that look similar.....

no its not beyond filing as mine was similar and I did file it and still put a 40 hours on it

the question is is the replacement 40 hours later worth the time that it takes.

for me it was as I had to wait for the parts (2 months effectively) but when you have it within a week I would not do it and simply change the thing out

Robert-Jan

Cheers for the advice! Will get some quotes.

Regarding the gear that I have removed in the pictures, should it be fixed?

I had a look in the parts manual of the huskies I have and it seems to be fixed ( cant remember it anymore when I had the engine open)
yet your engine is a different one and from the pictures it looks to me not a big issue as long it fits snugly together without play on the rotation direction.


Robert-Jan

Problem is, the thrust washer is the same diameter as the hole in the basket, so the basket moves from side to side as thick as the washer is. About 3mm movement total! I'm going to bond the gear in for now and find a basket that fits. Thanks.

I don't think its a problem as the clutch hub is in place and secured to the shaft.

the bit of movement that would be in place is only as far as the clutch hub.

Robert-Jan

Problem is, it is possible for the basket to come in to contact with the clutch hub. There is already evidence of contact between the outer clutch basket and the inside of the engine casing/clutch cover.

You need to see it to best understand the problem. I'm experiencing 3-4mm movement.......
Bonding the gear back in to the clutch basket will solve my problem short term.

Filed the fingers, they look like they will be good for now. I'm not going to be doing any racing starts on it!

you can also look for a spacer ring but you might get in the problem with the length(to short) of the clutch actuation shaft
Robert-Jan

found this file

would be a nice help for you

Robert-Jan

I had the exact same problem with mine Dan, any basket from a 125 will fit it.
They changed the basket design but they are interchangeable.
That basket has had it! The gear is press fitted into the basket & shouldn't move, let alone drop out.