Clutch problem

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grillbritt

Joined
Jul 21, 2008
Messages
52
Location
Sweden
Hello

I had to buy a new inner clutch hub to my 04 so I looked in the manual and it says 590.32.002.200.
When I ordered from my dealer he said that it was replaced with 590.32.002.500 which is from a 2007.
When I replaced the part the clutch didn't work, it only "slides". So I took it apart again and started to measure. And I have assembled it twice just to make sure I didn't place two steel/aluminum plates together.

My friction plates is only 1.87 mm wide and the scoop where the locking washer holds the two half washers is 0.1 mm deeper in my old clutch hub.
Excuse my technical english, but I hope you understand anyway.

Do you think the combination of the plates and the scoop depth could be the problem, so I have to buy new friction plates aswell?
 
What was your intial concern? Why did you have to replace the hub?
 
I had to replace it because I'm a fool :) I managed to break it when I took it of when I changed the camchain...

Yes I know... I'm an *****
 
grillbritt said:
I had to replace it because I'm a fool :) I managed to break it when I took it of when I changed the camchain...

Yes I know... I'm an *****
Click to expand...

been there, done that :oops:
 
maybe the dealer told you about the clutch drum but not about other things that may have changed such as plate thickness? check for these things. not sure whether your year has one but there is a tiny, tiny shim that goes on the end of the clutch push rod inside the pressure plate shoulder.

if you have this missing when you should have one - this could be the problem? just an idea.

ask your dealer to look for "other" parts that got changed.

regards

Taffy
 
I'm waiting for an answer from my dealer now.

I compared the two different years and all that I can see that changed from mine is the clutch drum (which I have) and the spring retainers.

The 2004 dimensions is 6,2X12X18X3,6
The 2006/2007 is 6,2X12X18X5,2

Do you think these 3,6 vs 5,2 could be the problem? What does all the dimensions say?

Taffy: http://img42.imageshack.us/img42/6038/koppling.jpg
Is it any of those I marked that you mean? If so I have them on my bike.
 
it would go on the end of the rod #54 but it doesn't appear to have one.

please explain where this different dimension is? i don't understand what you have measured?

regards

Taffy
 
Ok, I can't find the tiny little shim that you are talking about on the years 2004-2009.

Have a look here: http://img195.imageshack.us/img195/6038/koppling.jpg

I have drawn an arrow. On the backside of the drum (you can't see it on the picture), where the washer marked 9 is supposed to be. The depth of the sleeve where the arrow points is 0,1 mm deeper on my old drum.

And I have also marked the spring retainers marked number 6.
 
i don't know what you have measured here?

6,2X12X18X5,2

i don't think 0.1mm makes any difference here. and what about #6? have you lost one?

regards

Taffy
 
Sorry about the confusion...

The 6,2X12X18X5,2 is the dimensions of the 07 springretainers. I have not lost anyone but the spring retainers on my bike is 6,2X12X18X3,6. Could that cause the problems.

I have a feeling that the 0.1 mm could be the problem. I read in the manual that new friction plates is 2 mm and should be replaced when they are 1.9 mm thick. Thats only 0.1 mm wear...
 
i don't think the spring caps are the problem. or the 0.1mm around behoind the drum.

sometimes the pressure plate just doesn't pack down onto the plates.

have you still got a washer next to the gearbox bearing?

i'm out of ideas.

BTW, if you know anyone coming to the UK in the next week i have an engine i'm trying to get back here from NW of goteborg (sjovic on the mjorn).

regards

Taffy
 
Ok. You think I should try to replace the drum again, and how do I get the pressure plate to pack correctly?

What washer next to the gearbox?

I live 10 km from Sjövik!! Cool! Sorry, I don't know anyone going to the fish 'n chips country :)
What's your engine doing over here? Or are you helping someone from Sjövik?
 
sometimes the pressure plate just doesn't pack down onto the plates.
Click to expand...
i think taffy's on to something here. you can misalign the pressure plate and not have it seat against the clutches. the telling sign is that you cannot start the spring bolts by hand.
the problem is usually when a steel plate sticks to the pp and keeps it from fully dropping.
 
i'm buying an engine off a patrik. could be a trade selling it ( a husaberg bike shop)? maybe if we talk about the clutch for ever and a day someone english or swedish can do me a favour for a 'drink'.

you do have 8 steel and 7 friction yes?

the 2003s had 1.8mm clutch plates and then they went to 2.0mm plates.

i still can't remember what year you have there?

regards

Taffy

regards

Taffy
 
Thanks for the help guys! I will try to replace the hub as soon as I have some time...

Is it a good idea to oil the plates and friction plates before assembly?
Yes I have 8 steel and 7 friction. It's a 2004 so the thickness should be 2mm.
But mine is only 1.87 mm...
 
i don't oil them. the engine drags so much you can't start them. then when they are started they coat themselves immediately and all is good again. another tip is to start it and then lay the bike on the left as it sits on tickover. same thing - different way...

regards

taffy
 
I'm getting crazy and ripping my hair! I bought new friction plates and have fitted them, but the clutch won't work at all! It's like holding the clutch handle all the time...

I have tested tipping it on the left side with the engine running, but no luck...
 
you need clutch steels replacing i reckon, just sorted a lads bike out what was doing the same. I have an ok set of them here for sale...£15 plus postage to you
 
grillbritt said:
I'm getting crazy and ripping my hair! I bought new friction plates and have fitted them, but the clutch won't work at all! It's like holding the clutch handle all the time...

I have tested tipping it on the left side with the engine running, but no luck...
Click to expand...

suggest that you undo the three screws in the hydraulic clutch slave by 2 turns EXACTLY. then pull the lever. if the CS moves outwards then the action is good but if it doesn't = that has packed up.

if it works you need to pull the left cover and check that the clutch pressure plate is moving in and out.

report back here.

regards

Taffy
 
I had massive grooves on the inner clutch hub from where the plates constantly knock. I just smoothed them out by sanding them down.. it took some time.

Them grooves will prevent plates from free movement, i beleive... mine defenately had a better feel afterwards. To be clear, I did not have a slipping clutch before doing this either.

Worth a try if the slave is OK,

Anders, DK
 

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