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

Jo Rhett jorhett at
Mon Aug 12 10:53:13 PDT 2013

To be honest I really just retained "they look similar but are not the same" in my mind, and since I wouldn't change anything other than clutch plates without Zoran's advice I forgot the rest.

On Aug 12, 2013, at 10:07 AM, Chris Burgess <chris at> wrote:
> 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.
> -Chris
>> 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

More information about the SV650 mailing list