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.
Pro Build WERKS baskets get a second bearing installed in the outer plate. This stabilizes the basket under load making smoother shifts and less vibration.
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. Top/outer plate gets removed. Belleville washers are inspected and cleaned. Springs are inspected and cleaned. Springs are coated factory color on Pro Build baskets. Steel gear is machined on main bearing surface for smoother finish and correct position. Pro Build baskets get other side of gear machined also for the outer plate bearing to run on. Inner plate is cleaned and machining process started. Rivets are pressed out of the aluminum. Basket is threaded for high strength low clearance fasteners. Basket and inner plate are machined so they can be locked together permanently. Basket is then bored to accept a bronze bushing which is pressed into the aluminum basket. This bushing is then machined to fit the already machined bearing surface on the big steel gear. On Pro Build baskets the outer/top plate is machined to accept an in house machined bearing. Once this is fitted the bearing is bored to fit the steel gear. Once everything is complete and all parts receive a final cleaning they are assembled on a jig fixture to align and time all parts. There are more details, some cosmetic, some proprietary that go into what becomes a WERKS modified clutch basket.
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Clutch shop will be closed Thursday 9/23 through Tuesday 9/28. No shipping or clutch builds during this period. Quiet Ride sales not effected.