Anyone have a 2006- 2007 tc/te 450/510 clutch basket sitting around?

[Soviet]

I'm looking to convert my older 2004 TC450 to a newer clutch basket so I can utilize a rekluse auto clutch. Wondering if someone out there has a clutch basket sitting around and wouldn't mind taking a measurement for me. Dealers aren't much help and I don't want to spend the money on parts if it won't work. If the measurement works out, I'll be on the hunt for a newer clutch basket so I can get a z-start pro in my bike. Thanks for the help!

 

[Colo moto]

Try calling Sean at Rekluse. He has always been very helpful to me. If I remember correctly there might be some issue with different splines on the different years? Don't quote me on that, but I seem to remember something like that.

 

[Soviet]

Try calling Sean at Rekluse. He has always been very helpful to me. If I remember correctly there might be some issue with different splines on the different years? Don't quote me on that, but I seem to remember something like that.

I have heard about different ratio's on the gears, which seems to be very common throughout the years. I was thinking if the basket itself could work, that I could take the gearing from my basket and install it on the newer basket.

 

[Pinittowinit]

Sorry to say it won't work. The gear can't be replaced on the 04. And the newer basket won't fit. It fits the shaft but the teeth aren't the same. Also the shafts are different lengths. But that can be fixed easily. But anything can be done. Just depends how bad ya want it.

 

[Soviet]

Thank you very much for the reply and pictures. What about it I replaced the matching gear on the crankshaft from a newer unit as well so the gears would mesh correctly so I would be using a gear set-up from an 06 model instead of the 04? Does the 04 model have the longer or shorter shaft of the two? By the pictures it appears the bearing surfaces for the basket appear equal.

 

[Pinittowinit]

If you swapped the sprag clutch or some call it the starter clutch, then I reckon it would work. I do have a complete clutch assembly for sale. I had an idea to simply it. You could just have a new gear made for the new basket assembly. Or maybe a 610 has the same basket with the 04 gear ratio. Or instead of making a new gear you can have the new basket machined down and a new ring pressed on with the old ratio.
Wait a sec why do any of that.... I'm sure rekluse says it won't work because the baskets are different. They might not know the differents is the gear ratio. Let me look into this right now.

 

[Soviet]

Good call on the starter clutch. I entirely forgot about that gear. I'll have to get that too. I have a lead on some 2006 bits from a TC450. Namely the basket and hub. I'll ask if he has the start clutch and crankshaft gear that matches the set-up.

 

[Pinittowinit]

Ok so check this.... Why do you need a new basket? I'm willing to bet rekluse says it won't fit because the baskets are different.
Now I just spent a hour looking at the parts breakdown. The clutch plates are the same, as well as the outer part of the clutch hub. The part that gets the springs.
Now I know the shafts are different in length. I'm almost positive the 04 has the long one. Try to stay with me here... I'm willing to bet that the 05-07 will fit but you will need the 05-07 washer that sits behind the hub.
In in Cali on business until Christmas otherwise I would swap the stuff to prove or disprove my theory. I have both engines.

Also to throw you off even more... Lol the entire clutch assembly is the same from 05-07 in 08-10 they changed it for a wider clutch pack. Has more surface area for grip. Anyway you can put a 2010 entire clutch assembly in a 05. You just need the pushrod as well. I have a 06. And when I rebuilt it I put a 09 txc clutch assembly in it. Then a few months later dropped a stm slipper clutch from a 2009 450rr. Direct swap

 

[Soviet]

Dood. Thanks a bunch for checking on all that. I also did some digging. My 04 only has electric start. So I wouldn't need the kick starter sprag gearing or any of that set-up. I checked and the entire electric start gearing is the same from 04 and up. So I would really only need to swap out the basket, and matching drive gear on the crankshaft if I wanted to go to a newer set-up. I also noticed the clutch plates and pressure plate share the same part numbers for a whole bunch of years. The newer bikes have gearing better though. The 04 has a 27 tooth crank gear, the newer bikes use a 23. That would give it alittle more bottom end and eliminate the extremely tall 1st gear. Heck, I rarely hit 3rd gear in the dirt.

Still, your idea of doing nothing and getting a Rekluse in there is very tempting. I already put up a wanted posting in the forums for a rekluse. Once I have it all in front of me I'm certain something can get worked out. I'm guessing I will need to have a spacer of some form worked up to correct the difference but I'm thinking something could work. I think the worst case scenario would be me needing to install the 06 basket and crank gear and building the correct spacers.

 

[K5PL5]

Dont know if you're still looking but Ive got a clutch basket with discs like brand new from my 2007 SM510R. The bike only had a few miles on it and had a slipper installed.
I've got a stock piston and rings from the 510 as well..

 

[Pinittowinit]

http://www.cafehusky.com/threads/re...ch-04-05-tc-te-450-510-04-07-tc-te-250.29471/

 

[Soviet]

http://www.cafehusky.com/threads/re...ch-04-05-tc-te-450-510-04-07-tc-te-250.29471/

You know that's my ad right? I didn't have any luck getting it to work as I mentioned in the ad. That is entirely why I'm trying to update to the 2006 model so then I can use a Z start pro. Thanks for the look out.

 

[Soviet]

Ok so check this.... Why do you need a new basket? I'm willing to bet rekluse says it won't fit because the baskets are different.
Now I just spent a hour looking at the parts breakdown. The clutch plates are the same, as well as the outer part of the clutch hub. The part that gets the springs.
Now I know the shafts are different in length. I'm almost positive the 04 has the long one. Try to stay with me here... I'm willing to bet that the 05-07 will fit but you will need the 05-07 washer that sits behind the hub.
In in Cali on business until Christmas otherwise I would swap the stuff to prove or disprove my theory. I have both engines.

Also to throw you off even more... Lol the entire clutch assembly is the same from 05-07 in 08-10 they changed it for a wider clutch pack. Has more surface area for grip. Anyway you can put a 2010 entire clutch assembly in a 05. You just need the pushrod as well. I have a 06. And when I rebuilt it I put a 09 txc clutch assembly in it. Then a few months later dropped a stm slipper clutch from a 2009 450rr. Direct swap

So it's possible you're right. I just purchased a rekluse z start pro clutch for an 06+ 4 stroke and attempted to figure out what is different about the years. Well, like you thought, the basket from the 04 is usable i think. As it sits, the pressure plate wont engage the basket enough, so I simply removed the factory washer that goes in between the basket and the hub, and voila! The rekluse fit darn near perfectly. I'm certain i have changed some geometry though, so I'm going to figure out what else I'll need to shim, or adjust, and see if I can get this rekluse to work in here. So far no parts have been needed or modified. I simply removed that spacer. More updates later as I finish and test the function, clearance, etc. I can't imagine there is any issue of not running the spacer in there...

 

[johanv]

So it's possible you're right. I just purchased a rekluse z start pro clutch for an 06+ 4 stroke and attempted to figure out what is different about the years. Well, like you thought, the basket from the 04 is usable i think. As it sits, the pressure plate wont engage the basket enough, so I simply removed the factory washer that goes in between the basket and the hub, and voila! The rekluse fit darn near perfectly. I'm certain i have changed some geometry though, so I'm going to figure out what else I'll need to shim, or adjust, and see if I can get this rekluse to work in here. So far no parts have been needed or modified. I simply removed that spacer. More updates later as I finish and test the function, clearance, etc. I can't imagine there is any issue of not running the spacer in there...

So, any updates on this issue? Did it work?