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Hello All,
Need a little clarification on replacing the basket rivets in a KZ1000 . I spent some time searching didnt find what i was looking for. In the process of replacing the rivets and springs in the clutch basket, everything is set to go back together. I am wonder why the rivets are welded in, is it because the new rivets arent peened over and just welded in place or are they peened over and welded so they wont come loose?? 

I believe they are just welded. Probably need a pretty large press to peen them like the factory

Kawasaki used orbital riveting on the clutch baskets, the 650/750 clutches have rivets but are much smaller. Those large diameter rivets on the 900/1000/1100 clutches would be very hard to replicate without the proper sized fixturing and machinery. That process is not a straight punch down on the diameter but a rotary rolling down on the edge in a circular motion.

For the aftermarket suppliers welding is the easiest way around fastening the hub together after disassembly. It is the same for 650/750 clutch hubs, welding the rivets onto the steel top cover after replacing the rubber pucks is the easy way to hold the hub together.



 

If the rivets appear to be welded it's probably because the the springs have been replaced before.  I just replaced them in my kz1000 and it's not difficult. The trick is to be sure that the inner and outer spring retainer disks are compressed tightly as the bellville washer will be under tension. I was able to do this with two pieces of tubing. One against the rivet heads inside the basket and the other against the outer spring retaining disk. It was compressed in the hydraulic press and then welded. It could be done with three c-clamps as well.
 

Nice job Vinsky! Looks like you retained the different rate springs. Did you purchase the springs as a kit? And heck, since you've got this down to an art, want to out-source yourself and do some more?

Thanks All for the responses and answers. Got my fixture all made up to compress everything together for welding, might do it tonight ill post up some pics when i do.
 

I did this on the cheap, by filling the worn spots in the spring retainer disk with silver braze and stretched the springs with a wedge. The rivets were made out of 8620 bar stock, a bit oversize so every thing went together nice and tight.
It's all straight forward except compressing the parts together before welding the rivets.
Now if you want to rebuild a complicated clutch, try a Vincent clutch.
 

No thank you....LOL

Now i know where McCulloch got their design from, ha

asphalt900 wrote:

Now i know where McCulloch got their design from, ha
 

Decileration is what complicates the Vincent clutch.

Is there a common ground between the Vincent and the Brough Superior in clutch design? I happen to know a fella that has the largest North America stash of the Brough's. 

Brough never made a unit construction motor so used gear boxes and clutches from different manufacturers such as Norton.