Clutch reassembly troubles (Paranoid maybe?)

[RooK]

First things first.
I'm reassembling the clutch and I noticed some wear from the springs on the pressure plate. Should I worry about this or is this typical?
It's quite hard to say exactly what is the depth of it. (See pictures)



Then I noticed what appears to be a hairline crack in the inner basket radiating from the bolt threads.
So the question is, is this just regular casting or again should I put this on my shopping list too?


Lastly,

On reassembly, the nut doesn't fully thread so it partially sticks out of the shaft therefore the wavy washer sits on the nut lip. Now I don't have a picture of before, but it just doesn't seem right, I can swear it should thread another mm or 2 in. RIGHT?


The crank gear and the clutch gears are even at the front, the crank gear was a little wider at the back.

The outer basket is fully inserted into the oil sprocket drive and I didn't remove anything behind that.
Am I paranoid and this is all normal? It just doesn't feel right to me.
Given the bike history, It's not impossible that there is an extra washer behind the oil sprocket drive but I can't find a parts list view of that in the shop manual.

I'll post a couple more pictures in the next post.

 

[RooK]

View of gears (in mirror)

 

[RooK]

Not one comment!
Does this all look normal wear?

 

[Old N' Grumpy]

Give it a bit...someone will chime in.

 

[Joesmoe]

The Earth takes an entire day to make a full revolution -- patience is advised for folks who love to help and do so solely for the inner satisfaction of seeing a good captain be on the road again with a good machine.

 

[Pedro]

Check the part number on that nut ,there are two types one has a longer part in the front , looks like you may have the wrong one on there.

Did you insert a screwdriver or some thing else through the hole in the basket to allign the gears ,one on the basket the other on the crank . If not this will hold the basket out stopping it moving back into postion

 

[mr hunt]

+1 aligning the 2 gears is critical

 

[mr hunt]

...aaaaaand...The ox is slow though the earth is patient...

 

[mr hunt]

What have you torqued the nut to?

 

[warp9.9]

I'm on the road right now will post some later. But I would pull the basket easy job going back is where you need to use a taper pin punch or screw driver like Pedro stated above. all it does is allow you to align the back lash eliminator gear with the basket gear so it slides right in.
pictured below.

Since you have the internal hub out you might as well inspect the spring plate in the back Just remember the spacer goes between the basket and the hub that's the big washer you took off the input shaft right after you pull the internal hub.

Oh and take one of your clutch spring bolts and screw it into the hub (no Spring finger tight to the bottom) then turn it over and have a look