Barnett clutch install

M

motopsycho87

New member
Hi all, I'm looking to order a Barnett clutch from America;

http://www.ebay.co.uk/itm/like/Barn...0085&clkid=6854746083126168632&_qi=RTM1793412

1 - anyone know anywhere in the UK to buy one? or anywhere better?

2 - has anyone had any issues fitting one? I see from the link below that there are 2 different size center holes... does Barnett make 2, or do you get the smaller one, and if required, have to open it up? or is the big one ok to fit on both?

http://rekluse.com/NPDLC/1XX-XXX/19...0)/193-705A_Read Me First - GasGas Basket.pdf

thanks!!!
 
Arrived today, sexy bit of kit! Will fit next week and document the process
 

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OK, so I took the rear brake lever off, kick start, 7 or 8 clutch cover bolts, 6 spring retainers. Out come the clutch plates and centre hub, pein back the tangs on the lock washer, used a rattle gun to remove the hub but.

To remove the drive gear from the basket I just used an angle grinder to take the peined heads off then punched them through.

Sadly my cush rubber were knackered, I got them on order this morning, they are about ?2.60gbp each, so I ordered some springs too, now I wait...

I have noticed the hole in the basket is larger than the original, but this won't cause a problem.
 
So I thought I was going to get it back together today, but...

1 - The cush drive rubbers are about 3-4mm too thick, there are no different part numbers from 2006 to current... so god knows, maybe I have the 125 ones? they have a different part number...

2 - The backing plate that holds the drive gear onto the basket is oversized and would thus tighten up on the shoulder, and not sit in the recess, so I'm going to have to turn that down at work on Monday...
 

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The new backing plate looks suspiciously like the one from the 125 parts list... wondering if someone, or even gasgas have done some parts fiddling... (the 300 back plate is plain round)
 

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I have not had to do one on my gasgas bikes but the one for my 450X (from Henson) came with everything I needed. All I had to do was knock the drive gear out of the old one put it in the freezer put the new basket in the oven for 15 min. and set the gear in the hole.

Have you contact the seller maybe he can help. Surly someone on here has done one?
 
Well literally the parts gas gas has sent me are too thick, but the correct pattern, I can only assume this is due to parts juggling at the factory maybe, or perhaps the parts person picked up the wrong ones, nobody at gasgas UK until Monday to find out....

The back plate I've just got to turn a few mm off the o
OD at work. So hopefully back together by Tuesday now
 
The thinner ones turned up today and fit OK. (They're a bugger to fit!!) Letting the loctite cure, says 24hrs on the loctite 262 data sheet, so I'll leave it until tomorrow before it goes back in the engine... Fingers crossed
 
Back together exactly as it came apart but new basket, clutch doesn't disengage at all. Pressure felt at lever, and you can watch the center hub rise, but no disengage... Any ideas?
 
OK, so I tried packing it out more, the slave cylinder then reached the end of its travel...

So, I'm assuming it is because I used the thinner spacer to allow use of the cr250 clutch plates, so I'm gonna skim 0.5mm off the back of the inner hub tomorrow and see where i get...
 

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All together and working.

Only real problem was the fact I used cr250 plates with the Suzuki spacer. And the backing ring needed a little turning off.

Cr250 cush rubber are the correct fitting btw, which makes me wonder if the center hub is a direct fit too, that being said the GG center hub is 50gbp if bought from Spain anyway.

Clutch works well on the stand, still drags when in gear though (I've always had this problem). But selects neutral fine. I've had a good read up of all the 300 2t and pretty much everyone people complain about clutch drag, normally remedied with thinner oil. So I'll be trying the ATF DEXRON 6 I used before to get rid of it before the sticking and groaning became a problem.
 
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