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May 2nd, 2009, 06:09 AM   #1
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07 fs 650e clutch pressure cap failure

After of totaly 75 engine hours,I notice that clutch didnt work fine last time I use the bike.With wheels on air,rear wheel moved strong when I put 1st gear and the clutch lever was pushed to the bar.I new that was about time to change the clutch liner discs,so I disassemble the presure plate and I measure the discs.Hmmm a bit lower than 1.90,actually 1.86 .But then I saw something not very good.I think I am lucky,because If this crack in the presure plate was made different and the piece of metal couldnt holded from the spring bolt the engine might not work now ...How about material failoure?I want to learn what could probable cause that.What is your opinion?

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May 2nd, 2009, 06:11 AM   #2
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RE: 07 fs 650e clutch pressure cap failure

Sorry,I couldnt post photo in the topic.

Here it is: http://www.husaberg.org/index.php?set_a ... _photo.php
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May 2nd, 2009, 02:00 PM   #3
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over tightened?
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May 2nd, 2009, 10:15 PM   #4
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Fatigue, perhaps material not strong enough or sharp corner ie no radius a place for a stress riser to start from.

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May 3rd, 2009, 12:22 AM   #5
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have you mixed your years and models up? used clutch second hand? etc etc only it looks to me like the PP wasn't flat on the clutch plates and you kept tightening? if you changed the washers or the shims it would be enough?

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May 3rd, 2009, 01:53 AM   #6
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Actually this is the first time I dissasemble the clutch and the first time I ''slightly" touch the engine,or transmition,ok.It was never touched until now except some valve adjustments etc.So last person touched my engine was someone in Austria at factory.The engine have totaly 70 hours and I have never strip it.Thats why seemed strange.I had heard some stories about material failoures but mostly for 2004 models becouse of factory move to Austria and probable with different metals for parts.I dont now if this part produced by KTM or someone else,I just want to mention that because 70 hours is not to much for something like that I think.By the way,when I untight the bolts of the clutch doesent seem overtighted,I meen from factory.

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May 3rd, 2009, 09:45 AM   #7
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exactly! so there is something wrong with the assembly proccedure perhaps? you need to look at the parts list to see if everything is in there and in the right order?

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May 3rd, 2009, 12:46 PM   #8
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According to spare parts manual for 2007 650,pressure cap its ok( same code on manual 59032003500),springs and spring retainers seems to be the same from some measurments I took,also screws.Manual refer to the same dimantions for retainers,springs and bolts.Ok the springs its not 43 mm,its 42,5 but according to manual you can use them until they aproach the limit of 41.5 mm.I am not an engine specialist but I think that the assembling was ok.When I remembering the tension of bolts when When I unscrew them I was almost sure that clutch was installed normaly.I think that material failoure is what we are trying to figure out.I have heard about exactlly same failours in some STM slipper clutches for Ducati and if I remember correctly for 999.They had broken in the same point...

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