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March 14th, 2011, 03:20 AM   #1
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'02 501 Clutch issue.

Just tried to fit new friction plates to my clutch, it was worn out but not cooked. The new parts must be too thick, or I am?! There is no play at all in the clutch at all now , do I just need to find new four new plates 1mm instead of 1.5mm? Or, is there a simple way to remedy this? Is the clutch unique or can I fit a non OEM part? I should really be supervised with tools, but I have got this far and am determined to get it done. Someone told me you have to fit them in a specific order, I tried every which way to no avail. Any helpful suggestions please?
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March 16th, 2011, 01:24 PM   #2
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Re: '02 501 Clutch issue.

Originally Posted by husaferg
Just tried to fit new friction plates to my clutch, it was worn out but not cooked. The new parts must be too thick, or I am?! There is no play at all in the clutch at all now , do I just need to find new four new plates 1mm instead of 1.5mm? Or, is there a simple way to remedy this? Is the clutch unique or can I fit a non OEM part? I should really be supervised with tools, but I have got this far and am determined to get it done. Someone told me you have to fit them in a specific order, I tried every which way to no avail. Any helpful suggestions please?
my fault Fergus!

for anyone interested earlier Husey's run 1.8mm plates while later ones run 2.0mm plates. I can only get the aftermarket versions of the 2.0mm. so they overpack the clutch.

an answer is to do one of a couple of things:
fit just three new plates in the middle. know where they are and swop the other 4 after 6 months when all the plates are bedded in. or keep the plates but add a little 'pill' in the bottom of the pressure plate tube. the pill is about 1.5mm and sends back the shaft to it's normal position rather than the rod having gone 1.5mm through the engine. even this would be fine but the clutch slave tries to move 1.5mm and the shoulder of the piston goes up against the gearbox bearing you've all seen behind the slave's three screws.

Ferg is now upgrading to OEM plates and I'm re-embursing him. no problems!

regards

Taffy
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March 18th, 2011, 06:44 AM   #3
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Re: '02 501 Clutch issue.

That's good news, you're a gent and I'm not stupid thanks Taffy. Everyones happy!
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June 11th, 2012, 05:36 AM   #4
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Re: '02 501 Clutch issue.

I'm posting to this thread, not gonna make a new one.
Have a problem with the same year same cc bike.
Once bought it 2 years ago, have been riding it like 10 hours or so.
just changed the oil 2 hours ago.
OIL: Agip 5w-40 racing
Lately when engine was warm and was driving...geared down and holded clutch lever down, it blocked the rear wheel, when the speed was lower, if then wanted to leave on 1st gear, it made kinda like metallic bad voice down below, but clutch was half engaged I'd say.

When driving, felt no problems, used clutch to change gear to control, worked.

Also while cold and put in 1st gear, it most of the times wants to move forward, not staying, while clutch engaged. Also the clutch have made creaking noises rarely.
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June 11th, 2012, 08:21 AM   #5
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Re: '02 501 Clutch issue.

starting a new thread is easy and less confusing.
you have no real problem. a lot of them make that noise. some oils more than others.
your oil viscosity when cold causes it to creep. if it becomes a problem, try another synthetic oil.
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June 11th, 2012, 12:09 PM   #6
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Re: '02 501 Clutch issue.

Okay, I'll then start a new thread next time : ).
Anyways, thankyou for that answere about the noise. I wasn't too concerned about that one either, but about the other problem I described : O...thanks if anybody has time to answere.
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