What goes into a WERKS modified clutch basket
All clutch basket builds start with an inspection looking for cracks or bent parts. Put on a spin fixture to look for wobbles that indicate bent parts not seen easily.
This surface is soft aluminum. Not machined but as cast when manufactured. Large chamfer on each side cuts down on actual bearing surface area.
Aluminum is bored for a press fit bronze 660 bushing. Then the basket is centered to less than .001" of center and bored to fit the machined surface of the steel gear it rides on.
The clutch basket you ship to WERKS Parts is the clutch basket we build for you. Name is engraved into basket first thing after it is inspected.
Both new and used basket builds get exactly the same work done to them. While always nice to have a new part, there should be no performance difference or durability difference in the two.
New and used Suzuki baskets have a very rough anti-balloon band surface. Part of how they are cast. WERKS modifications on all builds include machining this band to get most of the rough markings out and remove excess material in places where it might effect balance.
All clutch basket builds start with an inspection and initial cleaning. Then the rivets are drilled out. From there all parts are removed, inspected and cleaned. All parts go through an intensive cleaning process. From there the steel gear is centered to within .0002" tenths in a 4 jaw independent lathe chuck. This allows the bearing surface on the gear to be machined to match the gear bore withing a tolerance of .0001-.0002". This is often off by as much as .006" from the factory! Bearing surface is machined to a much smoother surface than the factory provides. Aluminum basket then has its rivet posts threaded to accept higher strength button head fasteners. Next it is machined to lock the inner steel spring plate to the aluminum basket so it cannot ever move again. Then aluminum basket is mounted in the 4 jaw independent chuck and centered to under .002" runout. That is about as good as you can get with a cast part. Bearing surface is bore to fit an over size 660 Bronze bushing insert. Once that is pressed in, the lathe is then bored to fit the dimension needed to properly fit the bearing clearance of gear and basket to .003-004". That is tighter than the .005+ clearance in the factory part. The very rough cast Anti-balloon band is machined while centered in the lathe to remove excess material that might effect balance. Parts are cleaned again and made ready on the assembly table. There are proprietary details left out. But that covers the main parts.
Centering of the basket in lathe to make ready to bore for 660 bronze insert
Boring the basket
Finished installation and final sizing of main bearing
Final cleaning done. On assembly table ready to start final assembly
Springs fitted to Stage I, II, and III openings
After final spin fixture test, basket is now ready for packaging and shipping to customer
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