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June 9th, 2018, 08:53 AM   #1
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I Ride: 2014 Husaberg TE300
TE 300 clutch!

Hello,
I'm having some clutch issues and need some of your knowledge and wisdom to stop me from going insane and emptying my bank account!
I've got a 2014 husaberg te300 it's always had a slight bit of clutch drag but nothing too bad.
Recently though its got worse... The bike won't start or idle when in gear with the clutch pulled in.
Bits I replaced :
Oem master cylinder seal kit,
Oem slave cylinder seal kit,
Fresh fluid Dot 4,
New oem pushrod,
New slave cylinder tension spring,
New bleed nipple.

I've checked all the friction plates and they're over the 1.9mm minium - clutch never slipped.

Steel plates are as follows:
S plate 1mm
Next 1.3mm
Next 1.3mm
Next 1.3mm
Next 1.4mm
Next 1.4mm
Next 1.4mm
Next 1.4mm
End plate 1mm.
So... 2x1mm, 3x1.3mm and 4x1.4mm plates.
The plates aren't warped ive checked with a steel rule to make sure.
The basket doesn't have any grooves.

I've had the slave cylinder off and whilst holding the lever pressed the slave piston back in but it won't move so is holding pressure.
Also I've released the lever and pushed the oil back through to resivour and pumped it back so the slave piston is nearly out and made sure no bubbles are in the system...

Gear oil is 15w50 shell ultramax never had issues with it before its only 1ride old. Could be worth a change?

Really am running out of ideas now somebody please help!!

Last edited by Briceyberg; June 9th, 2018 at 10:41 AM.
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June 9th, 2018, 03:14 PM   #2
ede
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I Ride: Husaberg FE 501 2002
Hi Briceyberg,
  • can you bumpstart the bike?
  • Does it run good when bumpstarted?
  • Does it run better when running with choke activated?

Just to make sure it's running good at all. Otherwise the clutch is maybe not the problem!

Regarding the clutch...
The internet says the TE 300 clutch is a direct replacement with the 300 EXC / 250 EXC (KTM) clutch... The internet is so smart... So I tried to find a service manual for the 300 EXC and voila (https://kristofsx.com/) ...there you are. The EXC/XC-W Repair Manual states on page 211:
clutch facing disc - thickness: >= 1.9mm
Contact surface of clutch facing discs in outer hub: <=0.5 mm

The same measurements as for the SX-clutch...

I would say your clutch discs are fucked up...

EDE
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June 10th, 2018, 06:05 AM   #3
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I Ride: 2014 Husaberg TE300
Hello ede,
No I wouldn't be able to bump start it as it won't push with just the clutch pulled in.
When it's running it rides fine just when you stop with the clutch in or downhills with the clutch in it Dies.
I Use choke to start, then when it's up to temp it dies unless turn choke off then will idle lovely in neutral.
What was you saying about the clutch facing disk which ones that? And does that mean no greater than 1.9mm?
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June 10th, 2018, 06:46 AM   #4
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I Ride: 2014 Husaberg TE300
Just been doing some googling too >= 1.9mm means greater than or equal too but no smaller than 1.9mm which all my friction pads are 1.94mm so they all seem OK.im thinking maybe the pack has swollen maybe?
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June 10th, 2018, 11:37 AM   #5
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I Ride: 2014 Husaberg TE300
So put a longer pin in by the lever to make sure I was getting enough travel on the lever and its still s**t, going to have to try a new clutch pack and fresh gearbox oil and see if that works.
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June 16th, 2018, 03:32 AM   #6
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I Ride: 2014 Husaberg TE300
Update on the clutch:
Ordered and fitted new clutch pack.....
Works amazing now! no drag at all!
Thanks from TXThumper and ede
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June 16th, 2018, 04:25 PM   #7
ede
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Hi Briceyberg,

that's great - so the problem was only the worn friction pads. Did you actually measure the thickness of the new discs?
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