DR650 major clutch slip
 

Hi All,

I am currently in Northen lao, and I have a problem... After taking a back back road not marked on my map I encountered a big muddy hill. As it was verry deap and slippery mud and I am carring a lot of luggage I had to ride the clutch to keep control. Almost at the top of the hill my cluch even at full relese failed to engage the gears enough to make the top. I had to dismount and drive/push the rest of the way. After this I had verry little pull at any revers in any gear and had to ride slowley on the flat sections and push with a little throtel up the any hills.

Once off the dirt and on the highway the problem continued except for a few KM after a long down hill run I got some drive back and managed to get it to pull to arround 80kms.

I am now in a position to pull it apart but not sure what to look for. If I need parts they will take about 3 weeks to arrive so not sure if I should order a compleate kit just in case.
Thanks for you help
Cheers
Ben

A clutch kit for the DR runs about $150 in the US.
They include springs, steel plates and the friction plates.
EBC and DP are two brands.
I don't think Barret makes a 'complete' kit for the late year models, but does has the parts to piece one together.

Thanks Lone Rider,

I can find a Barnett $139 and EBC $99 kit on ebay both for the SE wich mine is. They both include Steal and ceramic plates springs which do you think is better?
Thanks

There's nothing jamming the actuating arm? Cable free and not seized?

Before you tear into the motor...:(

I am not familiar with the ceramic plates and haven't heard of people using them, sorry.
I've used the EBC kit without problems.

Thanks Guys,

I have opened the cover and inspected the clutch, to find the first friction plate is almost warn away. There are none of the ridges left and deep scoring all over the disc. The rest look ok but I think I will replace the lot and save the best ones as spares.
I hope the lao postal system works well!!

Thanks Patrick,

I tried Suzuki in Thailand and Laos and they have to order from Japan. I am currently Packpacking through China so I might be able to get a genuine one from Hong Kong otherwise my parents can get one in Aus and post it through.

Thanks for the advice on stopping to cool off, I will remember that one for next time. I have already droped the front to a 14tooth but maybe I need to get a bigger rear for the offroad stuff.

Thanks for the tip on soaking the plates will do that first.
Cheers
Ben

Big bikes have been banned in Laos, so you won't find any parts there. Thailand shouldn't be a problem.

I've bought EBC plates for a Honda CX500 and they were terrible. Major changes in clutch adjustment (free play) with changes in engine temperature. I've never heard of this problem before, so advise caution. Perhaps better stick with genuine parts.

If you are stuck and need to get going you can either pull the springs to lengthen them or add a washer under each spring.

I'm running a bigger rear sprocket for road use and have a smaller front sprocket for the rough stuff. Standard gearing is too tall on this bike for all but road use.

Are you one of the Aussies I met at the HU meet in Chiang Mai?

Cheers,
Peter.

Hi peter,

yep its ben from the HU meeting in Chang Mai! Had some adventures on terrible roads in Pongsali povince north laos.

I have spoken to a shop in Chang mai and he said he can order but from china then he would have to post to Luang Namta so it would take a month. i can get my folks to pick up genuine friction plates from my dealer in Aus and post express which i think might be the best option.

They are a little dearer but maybe the best option.

AS for laos and big bikes, there is no problems getting in and riding arround as they hardly have customs officals at boarder crossings. We had no problems and were never asked for papaerwork.

Hope your travels are going well
Cheers
Ben

Hi Ben,

Glad you are OK and it was nice to meet you, but I lost track of you. I actually went to Jungle Lodge to look you up, but you had already left.

I strongly suggest you replace the springs as well if you have given your clutch such a hard time. If in doubt, you can measure them with calipers, they should be at least 33 mm long.

Good luck,
Peter.