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Sorry to drag this saga out any further but does anyone know what the inner plate thickness should be be any chance?
Mine is .187" and I do believe it was thinned down as it's thinner than the outer plate.
I also think this can cause the outer edge of the centre to bind against the basket.

I have one on order from some odd website I found: https://www.nmtciastore.com/ and I have no idea when it's coming.

Thanks to Allan for tips on putting in the rubber pieces. I now have a bogus hub to use for the process.

Have not received your pm. The ones I have measures .178 on the inner and .209 on the outer.

Got the pm and called you but no answerb

I was in the shower. Ha!
Sam and I spoke. Thanks for all the help, everyone, and hopefully others will benefit as well.

Yes, I think we all learned something here. Who woulda' thunk it, an incorrectly machined clutch basket!

Thats a new one for me on that component, dimensional instability at work, or the wrong part, a trip to the lathe would fix it. Happens a lot with new bits. Good catch,

Nick, what’s the latest on your clutch issue?

Well the inner plate hasn't shown yet but the other new parts have.
I took your suggestion and did some careful grinding of the basket with my drill press. Finally got clearance and the clutch to operate as it should. (Yea!!!)
Current issue is a leaky, stripped drain/adjuster plug on the primary cover. I saw a video where Lunmad had the same problem and used what looks like
plumbing tape around the threads. Worth a try i suppose. Anyone suggest a better solution?

If your plumbing tape doesn’t work you might try to goggle small rubber expansion plug. I’m sure someone will come along with a better solution.

I like that idea! Ordered a couple styles on Amazon...because the teflon tape isn't working too great. I'll let you know how it works out.

Tap it out to the next size if there is enough meat around the hole. If it's 1/4", you may be able to find a 7mm bolt, as I have an Ossa MAR that uses a 7mm pinch bolt on the kick start arm (which strips anyway). There may even be enough meat to use a 5/16".
Tom

Face grinding the outer race on a drill press?
The later drain plug is (I believe) 1/2-20, not sure about the early plug. There is no room to drill out to the next foot&finger or metric size. You could thoroughly clean it with brake cleaner, spray a coat of mold release on the bolt and fill the void between the bolt and hole with JB Weld.

All good ideas and I learn so much here. I had never heard of a Dowty washer or mold release before. Looked them up.

The rubber plug arrived. I chose this one for the 7/16 hole and I believe it may be working!
It would only slide in maybe 3/4 of the way but as I tightened the wingnut, the exposed rubber ballooned out, hopefully insuring the seal.
You can see I screwed it down quite far. Loctite on the wingnut?


https://www.amazon.com/GP/product/B00IG43ZHW/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1

I'd like to try the JBWeld next time the cover is off. Lots of brands of mold release. Any preferences?

Well, I take it back - it seems to be leaking from that spot rather profusely. Noticed after a short ride so I maybe it's the heating up of the engine.
Back to the drawing board. Cover coming off to better assess.
I'd like to try the Loctite thread repair kit.

Nick, spend the money to purchase a Helicoil kit, bring the thread back to stock and use the correct bolt with a Dowty washer. Any thing else you try will only ever be a temporary half arsed repair that will fail. Fix it once, fix it right and fix it for good.

Rod

Not sure what the thread is but the other option is a time sert, its like a helicoil apart from it isn't a coil wire but a solid item threaded on both sides. With this you can fit it with bearing fit or blue locktite and it should completely seal the external thread which is often a cause of oil leaks.

I removed my previous post as I was thinking A65, where this part of the case is thinner and a thread insert probably wouldn't work.

However if still using the Dowty washer it should seal whether using helicoil or timesert.

Sounds right. The last one I bought from Uni-Thread Ltd in the UK. 7/16 X 18 BSF kit is about 35 pounds so currently about $45 plus $10 shipping. Reasonable and the last one shipped to Massachusetts in a week. I was amazed.

I could not do this "in situ" I'm not taking this motor out again anytime soon! I'd rather plug the hole with JBWeld!

Curious. My thread gauge says my plug is 18 tpi. (Greg Marsh Fastener database says 18). Vendors show the part as 7/16 x 16. (Can't find a helicoil kit for 7/16-16.)

Could this be the reason it is stripped?