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Alright, I just recently bought a Hinson clutch basket for my 2004 crf250R. The stock basket was beginning to notch quite badly, and I felt it was time. Well, I popped off the side cover, removed the pressure plate, springs, plates....and after a lot of ingenuity finally got the big locknut off and removed the inner and outer baskets (along with the lockwasher and two thrust washers). Well, I used a grinder to removed the rivets that held the ring gear on the back of the clutch basket, pulled off the thin plate, and removed the ring gear and the kickstarter gear that was pushed into the middle of the clutch basket. All the while, I'm following my Clymer's manual and the instructions that I received with my Hinson basket. Well, I followed the instructions, word for word, and put the entire thing back together. It looked like everything was in working order, but when I began my cleanup I found an extra washer. I have put up a picture of the washer below, and was hoping someone could tell me what it was and where it goes. I am fairly confident that it goes between the kickstarter gear and the basket, but I am not 100% sure. I have taken it to a bike shop and had them microfiche it, but naturally, the microfiche shows the basket and the ring gear assembly as one entity. The Clymer's manual and the Hinson instructions mention every lock and thrust washer used except this one....do I even need it? I hate putting my bike back together and finding extra parts, so if anyone has done this before and recognizes this part, please let me know. Thanks a ton in advance!




-Tony

I think you are right. I haven't done a Hinson clutch for about a year but as I remember there is a washer between the gear pressed into the basket and the basket. Call Hinson. They will know and they will want you to install their clutch basket correctly.

You're right, that washer does go between the kickstarter gear and the basket. We have 2 07 250Fs. I noticed the same thing you did after doing the first one. When I did the second bike, I put the washer in between the gear and basket. We have run both bike for two or three months and haven't had problems with either one.

thank you for the help! I would have hated to put the washer some place it didn't go. Got the bike back together and she's running great. Thanks again!

-Tony