Hi guys after 45,000 tortured miles my clutch has started too slip. Endless miles towing trailer, and 2 up touring, not too mention the trail riding have taken there toll.

So as part of my service im going too throw in a new set of friction plates.
Ive done loads of clutches before on all sorts of bikes. The clutch plates arrived today and upon opening the pack i noticed something.

1 friction plate has larger internal dia. This goes in first after the anti judder spring (haynes manual) then it says there are 2 other types of plates.

Yet the rest of my friction plates appear identical. I got the clutch from TRW, used them plenty of times seem on par with EBC for quality.
http://www.trwmoto.com/

My question is what is the difference between the other 2 types of plate?? Does it matter. All the other clutches ive used in the past have just had identical friction plates alternating with steel plates.

Heres a pic.



Top right is the first one too go in. Larger inside diameter.

Any help would be great. The rest of the procedure seems simple enough. Cheers
Jon

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To boldly go where no Tenere has gone before.

You pull a trailer???? Seriously???? And how much does it weigh and how much stuff do you load in it???

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(Now sold on, sob) 2011 Blue XT660X with gold wheels, was 26,500 km.
Engine mods: K&N Stage 1 filter, DNA Stage 2 filter, snorkel removed, Kev fuel mod fitted.
Plus: smoked Puig screen, Yam aluminium sump guard, Yamaha / Acerbis handguards, Givi Trekker aluminium side cases, Leo Vince X3 cans plus Kev front fork mod and Fender Xtender. Just fitted Michelin Road Pilot 3 tyres.

SOLD the XTX for a Super Ten 1200. And just bought a Raptor 700 so staying on here for some tips....

There are three different friction plate types in the OE clutch pack, plus the six steel plates. The different friction plates are identified by their tabs and whether notched or not.

Going from inside to outside (first plate in to last) they should be in this order:

<Damper spring and seat>
Friction plate type-3 with notched tabs (128mm ID)
Steel Plate
Friction plate type-2 NO notched tabs (119mm ID)
Steel Plate
Friction plate type-2 NO notched tabs (119mm ID)
Steel Plate
Friction plate type-3 with notched tabs (119mm ID)
Steel Plate
Friction plate type-3 with notched tabs (119mm ID)
Steel Plate
Friction plate type-3 with notched tabs (119mm ID)
Steel Plate
Friction plate type-3 with notched tabs (119mm ID)
<Pressure plate>

Your TRW plates all seem to have notches though???

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Thanks for your help guys, Im going too put it in and see, the only reason i can think of having the 2 plates of a different design is that maybe it makes the clutch almost 2 stage if that makes sense. In the yamaha parts book the 2 type 2 plates seem too have more filriction material on them.
But if the EBC plates are identical im happen too use the TRW.

Maybe as you slip the clutch the outer plates bite first and then the inner 2 bite hard as the clutch is fully engaged???

Just a theory.
Ill post up if theres any difference in feel when fitted.

As for the trailer.
Here it is.


And more detail here

http://www.xt660.com/showthread.php?t=22060

It weighs 60kg and can carry 90kg inside. ;-)

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To boldly go where no Tenere has gone before.

Jon, if my eyes don't deceive me, the two bottom right plates (on your photo) each seem to have one less notched tab than the other four plates of same inside diameter?
Maybe they can be the Type 2 plates Pleiades is talking about?

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2014 XT660Z - Barrett pipe, DNA stage1.5, Barkbuster hand guards and handlebars, Pivot pegs, Teknik suspension, Guard-it engine protector combo, B&B rear rack, Trax topbox.

Just been and checked them. All exactly the same. I contacted trw and they said they have sold 1000s of the kit (they fit a few bikes) and had no trouble.
Just as a final check i stuck them on the CMM (coordinate measuring macbine) at work today.

All are identical and suprisingly well made, too tight tolerances. Max tolerance on thickness of friction material was 0.02 mm, similar story for the metal ring and tabs max variation was 0.07 on one tab.

Sod it there going in.

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To boldly go where no Tenere has gone before.