Isn't the 250 clutch set up the same as the 500? The gear is INDIRECTLY bolted to the basket on the 500 trough use of springs. That way there is some give when a sudden burst of power is applied. If you did not see any springs when you made the basket change then maybe the 250 is different.

 

No the 250 has little rubber bushings that go between the ring gear and basket. No springs. I did take the case apart yesterday and checked the fit of the mains. They are super tight. No ovaling of the case. I need to get ahold of some Suzuki guru shop or old mechainic that use to race these things. Maybe they could give me some insight.

 

try csa ask for john 1 586 939 7433

 

Just a guess, but... since the counterbalancer's job is to counteract the weight/force of the piston, wouldn't it weigh the same or exert the same force as the piston? Your engine kit might have lightened the piston enough to throw off the balance and overstress the key.

You might want to try macdizzy.com. A subscription will run you like $10, which really sucks, but the people over there are extremely knowledgeable.

 

What's csa? I may have to give them a try same with the macdizzy. The piston is a Wiesco replacement. Wasn't lightend any by me.