Barnett friction plates hair too wide. File, freeze or other?

[dayrus]

I feel like I need to say "long time listener, first time caller."  I've learned a ton from the info in here, but finally have a question I can't find an answer too.

So the clutch on my '06 s2r1K started slipping under moderate throttle and all the friction plates are shot upon inspection.  I picked up a full Barnett pack to replace, but the tabs are a hair too wide to fit in the basket.  Every plate seems to be just that little bit off, regardless of orientation on the basket.  It will rest on the grooves, but will not slide in.

I thought about freezing, but then they would be wedged in way too tight back at room temp, so that probably not the best solution.

Am I crazy in thinking filing the tabs down to fit won't be an issue?  Seems that's the natural byproduct of use anyway.  The basket is in good shape, no excessive notching.  If it isn't a horrid idea, what is a good gap between tab and basket?

Replacing the basket isn't an option for financial reasons at the moment, any suggestions would be greatly appreciated.

[Speeddog]

Odd.

What part number do you have for the plate set?

Good gap is the smallest that will allow free movement of the plates.

Can you accurately measure the tabs, IE micrometer or caliper?

[dayrus]

Odd was my second thought, it followed "what the make the beast with two backs, really?"

Part 306-25-40002.  Old school manual calipers read 12mm wide tab on the nose and same gap on the basket, I mean they're so tight it's not even funny. 

The other plates had a gap I could nicely fit a .01 spacer in and were rather quiet.  Just no grab...

[Howie]

Year and model?

[DarkMonster620]

Year and model?

'06 s2r1K

[Howie]

'06 s2r1K

Oh, missed that reading the post.  OEM basket?

[dayrus]

I'm not the original owner, but looks like if its not factory original, its an OEM replacement.
The difference is so slight, half a swipe from a fairly new file on the tabs should provide the clearance needed.

[BK_856er]

Don't know about your parts, but fwiw I know Snyder used to sell pro-cutting baskets that were manufactured with narrow openings and the plate tabs were hand filed to fit for minimum clearance, minimum noise and maximum life.

BK

[dayrus]

Alright, so I wasn't that off if manual adjustment isn't unheard of with other manufacturers.

Got the filing done this morning while the coffee brewed, everything fits nice and snug all the way around.  Short 20 mile jaunt and it's shifting beautifully with what seems like less foot weight needed and noticeably quieter action/foot feel.  Most importantly, no rpm spikes with a heavy twist of the throttle.

Brilliant, thanks!

[kokis]

I will never buy Barnet regardless of it's cool name(sounds like some gun) after story when some friction material detached from plate and got to oil system causing engine death.