03 or 02 clutch???

wiktor · Sep 15, 2009

I have Berg FE 400e 2003 model.
Number on the frame says 2003
Plastics say 2003
Digital speedo is 2003
Front axle is like KTM 2003
Some things in machine are saying that it's the 03 machine and bike, and i'm 100% sure that it's the 03 bike but i'm confused because it seems that i have 02 clutch in my bike.

In my manual it says 03 model clutch has 2 diffrent thickneses mating plates and i have only 1mm thick plates.
Also pressure plate with bearing and sleeve looks like 2002 unit and not 2003.
Is it possible that PO put older model clutch because he couldn't get 2003 at the time or my engine is 2002?

I wouldn't be worried about the clutch being 2002 but i just can't get it working right, clutch is not dissengaging fully and i can't hit neutral and bike won't idle in gear. Since i ride tight trails this is anoying me because i'm stalling the bike often and can't hit neutral.

Is there a fix for my problem without buying whole 2003 clutch??? That would be way to expensive for me.

Thanks

Husaden · Sep 15, 2009

Yes, its possible. Iv'e got a 2003 on the VIN with a 2002 engine on it. I made a thread about it some time ago.

http://www.husaberg.org/index.php?name= ... highlight=

Hope this helps,

Anders, DK

Taffy · Sep 16, 2009

if you have a splined clutch drum (centre) then it's an '02. if you have the steel tubes around the drum you have an ''03 clutch. a new splined ('02) drum will give you neutral straight away.

what you will find is confusion over the clutch FRICTION plates. the later clutch needs 1.8mm plates and the earlier one needs 2.0mm. then you have the different steels. it sounds like someone has got these two sets of figures muddled. check the parts book VERY carefully and and then measure the parts in your clutch. afterwards, with the right parts. you should be good.

you can't change the clutch drum because the gearbox shaft is different in each year and early ones have a circlip and later ones have a 27mm nut and lock tab.

regards

taffy

Coastie · Sep 16, 2009

Answering your first question - I have an 03 with a splined 02 clutch also.

wiktor · Sep 16, 2009

I have splined drum and circlip on the gearbox shaft so i guess i have 02 engine... at least gearbox

I checked engine number and it says it's 03 engine, some things in top end says it's 03 engine but i don't know what is 02 clutch doing in my bike???

Taffy · Sep 16, 2009

they sometimes fitted old stuff in to use it up and get it out of the door.

regards

Taffy

wiktor · Sep 16, 2009

I'm disapointed...
I found out that i have 02 engine in 03 bike... i checked again for some things in top end like coolant bleed screw, bridges across valve check covers and things like that.

I also found out that i have 03 chain slider in there which is good because i have read somewhere that 02 had bad designed chain slider. I'm worried about other faults in 02 engines but i guess if some little thing was badly designed and engine didn't failed in 430 hours than it won't fail now... propably. Are 03 engines really so much better than 02 or i'm just disinformed?

Taffy · Sep 16, 2009

yes disinformed. the bleed screw came with the '04 engine. there is very little difference between the '02 and the '03 engine. the easiest check is 'so you have one oil drain bung or two on the right of the engine?'

don't panic, you bought it to ride it.

regards

Taffy

wiktor · Sep 16, 2009

I have only 1 oil drain SCREW, it's horribly big

Yes i bought it to ride it but i'm already wrenching

, alot. Ignition gone, timing chain flaping around and hard to start. I fixed timing chain, i'm still deciding what to do with ignition and at last hard start may be gone with new/rewound ignition.

I don't care i love my Bergie because it's the best bike i EVER rode and i rode many newer bikes... at least i learned about 4 stroke internals a little better

. I've mastered 2 stroke repairs and now it's time to add 2 more strokes.

I wonder how is it that Berg rides so much better than all other bikes??? Fantastic bike! If only i could get it to start on button i would love it even more!

husabutt · Sep 16, 2009

Re: RE: 03 or 02 clutch???

wiktor said:
If only i could get it to start on button i would love it even more!

The 03's started just fine on the button...............................just joking..........................bad joke sorry.........................

wiktor · Sep 16, 2009

Re: RE: 03 or 02 clutch???

husabutt said:
wiktor said:

If only i could get it to start on button i would love it even more!

Click to expand...

The 03's started just fine on the button...............................just joking..........................bad joke sorry.........................

It's not bad at all 8)

Hehe you really got me for a few moments :lol: 8O

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03 or 02 clutch???

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