XR650R Clutch

[trailsurfer]

What is the hot setup for the XR650R clutch?

My clutch is engaging close to the end of the release of the lever so I think it's time to take a look at it. I started to notice the problem when I was doing a technical section of a D37 dual sport ride. I had just installed a BRP stabilizer sub-mount kit which requires re-running the clutch cable because it raises the bars and stretches the cable. After the ride I saw that the cable was real tight and slightly engaging the clutch so I adjusted the cable but as I said it still engages at the end of the lever so I'm not sure if it's ok or not.

I know there are some guys here that have a ton of experience with this bike so please let me know what you think.

[frankstr]

Do you have the proper amount of freeplay at the lever...... ?

[Old_Man_Time]

If the bike has any weakness it has been the clutch. The average rider most likely will not run into this problem but competition riders have. You should be able to adjust it so that it grabs earlier if not you may have a problem. I would think if you did not have this problem before you made the mods that the changes made to the clutch cable because of the mods and not the clutch are to blame.

The Scott Summers site recommends adding an extra stock clutch plate which he says will make the clutch more responsive and last longer. Again he is a racer and therefore is more likely to expose the weakness of the XR650R clutch by his riding style.

[SaltyWalrus]

Mine is slipping when I get on it on tar. I do abuse it heavily to control the power in tight trails, but I would expect a couple seasons out of a clutch before worrying about replacement. It isn't like I've put a ton of miles on it. I am going to throw in an extra plate and see how much more life I get out of it. If Honda knows it is a weak point, why don't they do something about it after a year or two of the model run? Why don't they do something about the footpeg? I am surprized they haven't gotten sued a bunch of times over injuries from footpeg failure.

I think JackAttack and Irondude are on the right track. Ride European!

[frankstr]

I installed the extra clutch plate and had a much better and stronger clutch action and I'm sure the clutch will last longer........... ?

[SaltyWalrus]

Did it (or has it) last a long time after adding the one steel plate before needing all new plates?

[hill5150]

I installed the extra clutch plate and had a much better and stronger clutch action and I'm sure the clutch will last longer........... ?

I did the same thing and it works great.......................... ? Just dont remove the plate closest to the basket it has a slight curvature to it.....................

[TimBrp]

When this mod is done are you removing the judder spring and seat? The clutch paks on these bikes don't see enough oil to begin with. Adding extra plates could only make that worse. I put in a Hinson basket, barnett dirtdigger kit and Xr's only HD springs and could not be happier. Smooth release and pleny of grab. The bike doesn't skip a beat.

[Old_Man_Time]

When this mod is done are you removing the judder spring and seat? The clutch paks on these bikes don't see enough oil to begin with. Adding extra plates could only make that worse. I put in a Hinson basket, barnett dirtdigger kit and Xr's only HD springs and could not be happier. Smooth release and pleny of grab. The bike doesn't skip a beat.

No you leave the judder spring and seat. That would somewhat defeat the purpose of adding the extra plate.

[TimBrp]

True it would. I didn't think of that....DUH...

[trailsurfer]

Thanks allot for all the input guys!

I will say I love the bike, but on the "A" level technical trails I can really appreciate why allot of guys are riding the KTMs. Quite a bit lighter and the button can really make a big difference. But for long Baja style riding with no worries the big XR is tough to beat. I guess I need two bikes now. ??

[frankstr]

Still have the judder spring assembly........ ?

I have over a year with this set up and it never slips.........

[SaltyWalrus]

Thanks allot for all the input guys!

I will say I love the bike, but on the "A" level technical trails I can really appreciate why allot of guys are riding the KTMs. Quite a bit lighter and the button can really make a big difference. But for long Baja style riding with no worries the big XR is tough to beat. I guess I need two bikes now. ??

I used to be an "A" enduro and hare scramble rider. Now I just play ride with my buddies, some of whom still race. The BRP is definitely not the right bike to race in the woods, as it wears you down much more than a lighter bike. It is also a little slower in the super tight sections, you can't charge quite as hard down hills, controlling it in the mud with wipe you out, and it's a handfull for us short guys on gnarly uphills.

But...as long as I am not racing, I don't care. I don't have to ride 4 hours with little or no rest. I can blitz for 20 minutes, then rest while waiting for my buddies on their orange "race" bikes. And there is a certain satisfaction that comes with whooping them orange 2-smokes with a lumbering beast. (Sure, we know the BRP isn't nearly the disadvantage they thing it is, even in the tight stuff. But they don't have to know that!)

The only thing that really pisses me off are all the weak spots. Can you imagine if a KTM, Husky or Husaberg came with the list of weaknesses the BRP does?

"Congratulations on your new purchase. And by the way, you have to replace the front sprocket seal before it starts blowing oil and you ruin your motor. And the bushing your clutch rides on has to be replaced before it seizes up the whole works. And while your are tearing apart the clutch on your NEW bike, throw in an extra clutch plate or it will start slipping in a couple hundred miles. Oh yeah, you may break your footpeg off if you place too much of a load on it, but that is ok, noone has died yet. And make sure you don't get a bike with the rusty fork internals. No big deal if you do, it's covered under warranty."

A product like this, with the reputation in would create, would sink a company like Husky or Husaberg. It seems to me that Honda is taking advantage of its reputation for reliability.

I love my BRP and will probably keep it for years as my only bike, but I don't think I will buy another Honda.

Umm....sorry. I guess......well.........I guess I just needed to vent.

[trailsurfer]

Well said Salty. I guess for me the reliability issue outweighed everything else, you really don't have to worry too much about getting stuck in the middle of no-where. I have friends with well over 15,000 miles on their XR650's without any engine trouble. I bought the bike with the intention of dual-sporting and it has been awesome overall. I have made all the mods you speak of with the exception of the clutch which is why I started this thread.

As far as riding the tight technical stuff, the bottom line is the rider makes more difference than any bike, but on a long 100+ mile day, a lighter bike with the button will no doubt tire you less. I chose to try a A+ loop and it was every bit of that and it exhausted me, I made it, but it kicked my ass for the rest of the day. That told me I need to ride that stuff more and get in better shape. Bottom line:this is all too much fun! ?

[XR4DEZ]

Take everything out to the basket and put in 7 fibers and 6 steel OEM plates, this is the same clutch pack Honda Off-Road uses on their 650s. I like the feel and it has much better pull than the stock stack but I only use mine in the desert. I can just slightly touch it to control wheel spin in the rocks or tight ultra soft silt and sand corners and it does not slip a bit. As for life??? Only have about 2K on it. I'm really not much of a clutch abuser at all though. More often than touching my clutch, I'll short shift to keep from spinning.

[trailsurfer]

Thank you very much XR4DEZ, that is exactly what I was looking for.