TRW clutch kit 650 '04

Hello guys!

Got a new clutch kit from a friend of mine because my clutch started slipping at higher rpm and gears, when really flooring the bike...

So there are a few things that I can't sort out...

The stock steel plates seem to be exactly same thickness... But the TRW kit comes with 4 thicker and 4 thinner steel plates...

So how about the order of putting them in, is there a special sequence or is it just the clutch pack thickness of - I think for 2004 - 22.2mm?

Where to put the thicker ones and where the thinner ones?

Hope somebody can help, thanks!

Regards,
Alex

Taffy said:

2 thin ones to start
then 4 thick ones.
then two thin ones to finish.

the 2004 had this set up but in 2005-2008 they went back to thicker frictions and 8 thin steels.

Taffy

Click to expand...

Hey Taff,

If I set it up like this, the last friction disc is already outside the basket...so it seems that they are too thick...as the steels are...

I wonder why, because i bought the kit according to the specs of the trw homepage, saying they fit the 04 model...

I also tried some spacers between the pushrod and mushroom-shaped actuator below the clutch lid...i got it to work from 1st gear engaged, also gets going, but slips when reving higher or flooring it... immediately...

Oil is 15W50 Motul, but that I've been using for 3000km now without any issues so far...

I don't really get it...


Thanks,
Alex

Taffy said:

what do you mean; 'like this'?

if you put all 2.0mm frictions in you should still be ok with 8 x 1mm steels.

on the original fristions a 2.0 measured 1.85 with a vernier and the so called 1.8 measured 1.65mm.

cock up i know. you will keep trying all these people who don't work on husabergs day-in and day-out.....

Taffy

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Hey taffy,

With 'like this' I mean: i put in 2 slim steels, then the 4 thick ones, to end it up with the remaining 2 thin ones... If I do so, the pack is too high for the basket, the last friction is already above the 'claws' of the basket... So this can't be normal I guess...

As the TRW Homepage says, the frictions are 1.9 mm and the steels are 1.0 and 1.2mm... what I can't really believe, because I can see a big difference in thickness... And I doubt that a human eye can safely figure out a difference of .2mm... At least mine can't...

The sets are labelled the right way, saying, that it fits bikes from 01-06...

It really su.... And I don't want to keep trying... Got that kit from a friend of mine who had to of them, at least his 06 model works..... Otherwise I would have gone for the OEM ones, of course...

Thanks,. Alex

Taffy said:

stick to your old frictions and the new steels. introduce 2 new frictions a year.

Click to expand...

And it is just that what makes the clutch slip at higher rpm? That's what it the before the whole son of a diddly action got going.....

Thanks, taffy!