Premature clutch wear. 1st vs. 2nd gen?

Chris Burgess chris at
Mon Aug 12 10:07:24 PDT 2013

Why would Z say that?  I've used the Barnett clutch pack including springs in my 90hp 2nd gen for some time.  I loved the stiffer spring at the clutch lever.
I just completely rebuilt the motor (cases and all) and put in another Barnett clutch with springs. Just got it fired so no time on it.  
My question is how did you get the 1st gen clutch into a 2nd gen bike?  Are you using the 1st gen clutch basket? If so, why?
And what I would look at is oil.  What oil are you using and is the clutch getting enough.
> Subject: Re: Premature clutch wear. 1st vs. 2nd gen?
> From: jorhett at
> Date: Mon, 12 Aug 2013 09:18:30 -0700
> To: sv650 at
> Zoran told me not to use the Barnett springs in the 2nd gen clutch unmodified. I can't remember what else he said, but I'd check with him directly if he doesn't speak up here. Sounds like they are not-quite-the-same.
> On Aug 12, 2013, at 9:15 AM, Aaron Turner <synfinatic at> wrote:
> > So I've been trying to diagnose why my clutch slips under hard
> > acceleration.  It doesn't slip a lot, just what feels like one revolution
> > or so. Happens probably 2-4 times a lap at THill depending on how hard I'm
> > on it.
> > 
> > So long story short, I have a nearly brand new (2 race weekends and about 5
> > track days) 1st gen Barnett clutch pack installed in a 2nd gen motor.
> > (long story)   Although to be honest, the clutch has been slipping for at
> > least half that time (I've had bigger problems to worry about).  I tried
> > adding more play in the clutch cable last race round, but that didn't help.
> > 
> > The clutch seat & seat spring washers from the 2nd gen clutch are NOT
> > installed.  4 of the 6 clutch springs were Barnett, the other 2 stock.
> > 
> > I measured the plates.  The thicker #2 friction plate is on the high side
> > of being within spec.  Of the remaining 6 frictions, 4 are in spec (barely)
> > and 2 are just out of spec.  All +/- .02mm of spec.
> > 
> > Steels look good, no bluing/etc.  Pack was installed correctly per 1st gen
> > specs.
> > 
> > So, seems like I probably need a new set of frictions (I couldn't find any
> > spec for total clutch pack height, does anyone have any numbers?).  What I
> > don't understand is why the clutch wear was so aggressive.  The motor isn't
> > making crazy horsepower (less then 80HP) and historically my clutches have
> > no problem lasting more then a full race season.
> > 
> > I know the 1st & 2nd gen SV are *almost* the same... stator, gear position
> > sensor and oil cooler being the obvious differences on the bottom end, but
> > maybe there is something different with the clutch basket/etc that would
> > cause this premature wear?
> > 
> > Right now, the only idea I have is that the clutch cable was too tight and
> > that caused the premature wear.  And by the time I loosened it up it was
> > too late.  But honestly, I never felt any difference after adjusting the
> > clutch cable.
> > 
> > Suggestions or ideas?
> > 
> > Thanks!
> > 
> > 
> > Aaron Turner
> >         Twitter: @synfinatic
> > - Pcap editing and replay tools for
> > Unix & Windows
> > Those who would give up essential Liberty, to purchase a little temporary
> > Safety, deserve neither Liberty nor Safety.
> >    -- Benjamin Franklin

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