Clutch wear advice

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by COXR650L, Feb 13, 2018.

  1. COXR650L

    COXR650L Long timer

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    Im going to copper canyon in a few weeks. I have spent a ton of money getting my 950 ready. I really dont have any more to spend on the bike but am concerned about the clutch.

    The overall pack is 49.4 mm. The individual friction plates range from over spec, just at spec and a few are under spec.

    Ive read the minimum spec for the entire pack is 48mm. The manual only lists the individual friction plates and the 48mm came off the internet. Does anyone have advice? Is 48mm for the entire pack accurate?
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  2. DirtyADV

    DirtyADV Long timer

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    Cant help with overall measurement for the pack.

    But if a few are under why risk it, replace what are under spec. Dont see a real reason to replace them all.

    Also if checking clutch pack might be worth laying the steel plates on a flat surface (piece of glass) and make sure they are not warped.

    And measure the friction discs in a couple of places.

    /Johan
    #2
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  3. GoGoGavin41

    GoGoGavin41 Wheelie Ergo Sum

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    I'm not familiar with the riding in Copper, but if you expect to be feathering the clutch a lot you might want to replace.

    I personally replace when the clutch starts to slip / shifts become notchy. That has sometimes been the case when the friction plates are out of spec, and sometimes not.
    #3
  4. darkstarmoto

    darkstarmoto Am I evil? Yes I am

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    According to the service manual, yes 48mm is the wear limit.
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  5. gearheadE30

    gearheadE30 Long timer

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    1.4mm is more than it sounds like, for what it's worth. I don't think I'd be too worried, unless you're really hard on clutches.

    I haven't measured my clutch as a complete pack, but the fibers are all about smack in the middle of the thickness ranges after 85k hard miles. What I found is that the wear limit was actually the aftermarket clutch slave bottoming out (regardless of if things are in spec or not) - the aftermarket ones only have ~4mm travel where the stocker is close to twice that.

    If you're really worried about it, bring an extra clutch steel with you. If it gets too worn, you can always double stack the extra steel and it will give you quite a lot more time to get it sorted. It's like $10 or so of cheap insurance, doesn't take up much space, and takes 20 minutes to throw in on the side of the trail. It won't hurt anything to have two of them in there either, as they are all keyed to the inner clutch drum and they won't really be moving relative to each other.
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  6. COXR650L

    COXR650L Long timer

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    Thanks I'll leave it and take an extra steel.
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