Clutch noise could it be the basket

I don't think the grinding is causing this. Why? Assuming you only
ground down to the depth of the ridges, the clearance at the low point
should be the same as it was before you ground. Also, if this happens
when you aren't pulling in the clutch lever, then I would think you
would be experiencing clutch slip, as well.

I think you put something back in wrong or didn't torque properly.
Double check all that before you buy a basket.

As for the PE one, I have had one in my bike since late last summer,
and it has worked great. You will need the ring gear off the stock
basket, so don't trash it. (It's easy to remove with a grinder and
install with the supplied screws -- use red loctite for peace of
mind.)

James
00CR250

ps2112.TakeThisOut@aol.com (PS2112) wrote in message news:<20041014221339.24078.00002187.TakeThisOut@mb-m13.aol.com>...
 > Hello all
 > Well I got my motor all put back together and it runs great with the exception
 > of the clutch. While it was apart I filed the notches smooth, about .02- .03"
 > on each ear. Now it rattles something fierce. It has done this for a long time
 > although not this noisy. When I pull in the clutch the noise goes away. I took
 > it apart again and everything looks fine. The only thing I can think of is that
 > the width between the ears is allowing the plates to knock back and forth. I
 > did check the needle bearings and sleeve that the basket rests on but they look
 > great; I can still see the grind and hone marks, although the basket has a
 > small amount of forward backward play when it is all buttoned up. Is it time
 > for a new basket? I'm leaning toward the performance engineering unit. It's
 > billet, hard anodized and only $139.
 >
 > Thanks
 > Paul<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

It's a 99 Kx 250. When I did the transmissiion I left all the gears on
their shafts. I'm thinking I'll try and remove the cover and run it
without the plates and see if it is still making the noise.

Jeff Deeney wrote:
 >
 > "PS2112" <ps2112 DeleteThis @aol.com> wrote in message
 > news:20041014221339.24078.00002187@mb-m13.aol.com...
  > > Hello all
  > > Well I got my motor all put back together and it runs great with the
 > exception
  > > of the clutch. While it was apart I filed the notches smooth, about .02-
 > .03"
  > > on each ear. Now it rattles something fierce. It has done this for a long
 > time
  > > although not this noisy. When I pull in the clutch the noise goes away. I
 > took
  > > it apart again and everything looks fine. The only thing I can think of is
 > that
  > > the width between the ears is allowing the plates to knock back and forth.
 > I
  > > did check the needle bearings and sleeve that the basket rests on but they
 > look
  > > great; I can still see the grind and hone marks, although the basket has a
  > > small amount of forward backward play when it is all buttoned up. Is it
 > time
  > > for a new basket? I'm leaning toward the performance engineering unit.
 > It's
  > > billet, hard anodized and only $139.
 >
 > What kind of bike? Some have a split ring gear on the outside of the
 > clutch, where the split gears have an opposing spring load to eliminate
 > backlash noise. If that wasn't assembled correctly it would make a
 > lot of noise that would go away when the clutch is pulled in.
 >
 > -Jeff Deeney- ©2004 DoD#0498 NCTR UTMA BRC COHVCO AMA
 > jldeeney@c om c ast d ot net '99 ATK 260LQ-Stink Wheels '94
 > XR650L-DreamSickle
 > We don't stop riding because we get old, we get old because we stop riding.<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

That is what I'm thinking. There isn't a heck of a lot to put back
together wrong however. I'm going to run it for a few seconds with the
clutch cover off and see what is happening.

James wrote:
 >
 > I don't think the grinding is causing this. Why? Assuming you only
 > ground down to the depth of the ridges, the clearance at the low point
 > should be the same as it was before you ground. Also, if this happens
 > when you aren't pulling in the clutch lever, then I would think you
 > would be experiencing clutch slip, as well.
 >
 > I think you put something back in wrong or didn't torque properly.
 > Double check all that before you buy a basket.
 >
 > As for the PE one, I have had one in my bike since late last summer,
 > and it has worked great. You will need the ring gear off the stock
 > basket, so don't trash it. (It's easy to remove with a grinder and
 > install with the supplied screws -- use red loctite for peace of
 > mind.)
 >
 > James
 > 00CR250
 >
 > ps2112.TakeThisOut@aol.com (PS2112) wrote in message news:<20041014221339.24078.00002187.TakeThisOut@mb-m13.aol.com>...
  > > Hello all
  > > Well I got my motor all put back together and it runs great with the exception
  > > of the clutch. While it was apart I filed the notches smooth, about .02- .03"
  > > on each ear. Now it rattles something fierce. It has done this for a long time
  > > although not this noisy. When I pull in the clutch the noise goes away. I took
  > > it apart again and everything looks fine. The only thing I can think of is that
  > > the width between the ears is allowing the plates to knock back and forth. I
  > > did check the needle bearings and sleeve that the basket rests on but they look
  > > great; I can still see the grind and hone marks, although the basket has a
  > > small amount of forward backward play when it is all buttoned up. Is it time
  > > for a new basket? I'm leaning toward the performance engineering unit. It's
  > > billet, hard anodized and only $139.
  > >
  > > Thanks
  > > Paul<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

Be carefull, I ran a chainsaw with only half the clutch assembly (of course
I know totally different creature) and part of it came off and embedded
itself into the beam in my ceiling, luckily not into my skull,

ps2112 enlightened us with:
 > That is what I'm thinking. There isn't a heck of a lot to put back
 > together wrong however. I'm going to run it for a few seconds with the
 > clutch cover off and see what is happening.
 >
 > James wrote:
  >>
  >> I don't think the grinding is causing this. Why? Assuming you only
  >> ground down to the depth of the ridges, the clearance at the low
  >> point
  >> should be the same as it was before you ground. Also, if this happens
  >> when you aren't pulling in the clutch lever, then I would think you
  >> would be experiencing clutch slip, as well.
  >>
  >> I think you put something back in wrong or didn't torque properly.
  >> Double check all that before you buy a basket.
  >>
  >> As for the PE one, I have had one in my bike since late last summer,
  >> and it has worked great. You will need the ring gear off the stock
  >> basket, so don't trash it. (It's easy to remove with a grinder and
  >> install with the supplied screws -- use red loctite for peace of
  >> mind.)
  >>
  >> James
  >> 00CR250
  >>
  >> ps2112.TakeThisOut@aol.com (PS2112) wrote in message
  >> news:<20041014221339.24078.00002187.TakeThisOut@mb-m13.aol.com>...
   >>> Hello all
   >>> Well I got my motor all put back together and it runs great with
   >>> the exception of the clutch. While it was apart I filed the notches
   >>> smooth, about .02- .03" on each ear. Now it rattles something
   >>> fierce. It has done this for a long time although not this noisy.
   >>> When I pull in the clutch the noise goes away. I took it apart
   >>> again and everything looks fine. The only thing I can think of is
   >>> that the width between the ears is allowing the plates to knock
   >>> back and forth. I did check the needle bearings and sleeve that the
   >>> basket rests on but they look great; I can still see the grind and
   >>> hone marks, although the basket has a small amount of forward
   >>> backward play when it is all buttoned up. Is it time for a new
   >>> basket? I'm leaning toward the performance engineering unit. It's
   >>> billet, hard anodized and only $139.
   >>>
   >>> Thanks
   >>> Paul<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

I took it apart last night and ran it without the cover. It was really noisey.
After tearing everything apart, inspecting, detecting, and rechecking I went to
the trusty manual. It says, with big black letters and black and white
semi-glossy photos( with dimensions), that if the clearence between the clutch
dogs and fingers of the basket is too great the clutch will be noisey. I
measured said gap and found it to be .045-.05. The fine book say that the upper
limit of said gap is .033 and that standard is .003-.012. I reckon it's time
for a new basket.
 >> Stay informed about: Clutch noise could it be the basket 

"PS2112" <ps2112 RemoveThis @aol.com> wrote in message
news:20041016120009.11054.00002061@mb-m14.aol.com...
 > I took it apart last night and ran it without the cover. It was really
noisey.
 > After tearing everything apart, inspecting, detecting, and rechecking I
went to
 > the trusty manual. It says, with big black letters and black and white
 > semi-glossy photos( with dimensions), that if the clearence between the
clutch
 > dogs and fingers of the basket is too great the clutch will be noisey. I
 > measured said gap and found it to be .045-.05. The fine book say that the
upper
 > limit of said gap is .033 and that standard is .003-.012. I reckon it's
time
 > for a new basket.

You read the instructions?!?!?!? You obviously don't belong in
this NG

-Jeff Deeney- ©2004 DoD#0498 NCTR UTMA BRC COHVCO AMA
jldeeney@c om c ast d ot net '99 ATK 260LQ-Stink Wheels '94
XR650L-DreamSickle
We don't stop riding because we get old, we get old because we stop riding.<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

"PS2112" <ps2112 RemoveThis @aol.com> wrote in message
news:20041016120009.11054.00002061@mb-m14.aol.com...
 > I took it apart last night and ran it without the cover. It was really
noisey.

"without the cover".. as in low or no oil...and no cover to muffle the gear
noise... ya, its gonna be noisy..
But it does sound like you need one anyway so you might as well change it .

 > After tearing everything apart, inspecting, detecting, and rechecking I
went to
 > the trusty manual. It says, with big black letters and black and white
 > semi-glossy photos( with dimensions), that if the clearence between the
clutch
 > dogs and fingers of the basket is too great the clutch will be noisey. I
 > measured said gap and found it to be .045-.05. The fine book say that the
upper
 > limit of said gap is .033 and that standard is .003-.012. I reckon it's
time
 > for a new basket.<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket 

I went ahead and ordered a Performance Engineering basket. I hope this
fixes the problem. I'd hate to have to split the cases again

flymx wrote:
 >
 > "PS2112" <ps2112.TakeThisOut@aol.com> wrote in message
 > news:20041016120009.11054.00002061@mb-m14.aol.com...
  > > I took it apart last night and ran it without the cover. It was really
 > noisey.
 >
 > "without the cover".. as in low or no oil...and no cover to muffle the gear
 > noise... ya, its gonna be noisy..
 > But it does sound like you need one anyway so you might as well change it .
 >
  > > After tearing everything apart, inspecting, detecting, and rechecking I
 > went to
  > > the trusty manual. It says, with big black letters and black and white
  > > semi-glossy photos( with dimensions), that if the clearence between the
 > clutch
  > > dogs and fingers of the basket is too great the clutch will be noisey. I
  > > measured said gap and found it to be .045-.05. The fine book say that the
 > upper
  > > limit of said gap is .033 and that standard is .003-.012. I reckon it's
 > time
  > > for a new basket.<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Clutch noise could it be the basket