Honda CR250 1999 Clutch inner hub not spinning.

[Sandblaster]

A customer came in with a 1999 CR250 and the inner clutch hub was not spinning after the nut was torqued to spec.
If he backed the nut off a little the inner hub would spin freely.
A quick inspection did not reveal anything that looked like a problem.
So I went to a few other web forums trying to glean some information.
I even called a certified Honda mechanic.
I could not believe some of the answers I received.
The Honda mechanic told me that he just backs the nut off until the inner hub spins and then he folds the set tabs over
So we looked a little harder and found that the small gear on the back of the clutch basket stuck out away from the back of the basket.
This is what a good basket was measured at:

99 CR250 CLUTCH BASKET -1.JPG (27.12 KiB) Viewed 11632 times

I could not find any specs for this in the Clymer Service Manual.
But as you can see ours measured .3995" or 10.15mm.
The customers measured 0.4232" or 10.75mm.
So, the customer is going to press his gear back to our measurements.
He will support the basket by the steel rivets and press it from the small gear on the back

Support from this side on the steel rivets.

99 CR250 CLUTCH BASKET -2.JPG (18.2 KiB) Viewed 11632 times

He will press from this side on the gear with a block of wood to keep from marring the gear face surface.

99 CR250 CLUTCH BASKET -3.JPG (22.4 KiB) Viewed 11631 times

I will let you know if this works.

[Sandblaster]

Problem solved