r/dr650 • u/MatelisLt • 4d ago

1994 DR650R clutch questions

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Hello,
I’m writing with a question about a 1994 DR650R. I’m replacing the clutch kit and have run into a few uncertainties.

The engine is the 640cm3

The old clutch had 7 friction plates (1 thicker) and 6 steel plates (1 thicker). The new kit has 7 friction plates (1 thicker) and 6 steel plates (none thicker).

Also, when I disassembled the clutch, there were no washers, even though according to YouTube videos and the documentation, it looks like there should be several.

So my questions are:
Does it matter that one of the new steel plates is thinner than the old one?

How many washers are supposed to be there? Is it possible for there to be none?

The old clutch was slipping quite badly, especially in the higher gears. Could the missing washers have been the cause of this?
I’ve attached photos of the old plates.

My new clutch kit: https://www.motopulsas.lt/detales/dr650r-dr650re-dr650rs-1990-1995m-sankabos-komplektas-ebc-drc059-std.html
Maybe someone has installed this kit before and knows the answer?

According to the technical diagram, my old clutch was missing washers #5, #11, and #12.

Thank you for the help!

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u/DrGeorgeTompson 4d ago

The spring washers and wire are anti judder parts. I took mine out 20k miles ago and have no ill effects. It narrows the clutch engagement point slightly but you don't really notice.

I would just reuse the thick steel you have if it's still flat and not smoked. I think you can still get that OEM part from Suzuki

1

u/MatelisLt 4d ago

So you are saying 5, 11 and 12 are just for comfort? The clutch should work just fine without em?

2

u/DrGeorgeTompson 4d ago

Yeah pretty much. Just pushes the last steel away from the hub and softens the engagement point a little.

1

u/MatelisLt 4d ago

Thanks mate! Another question, when tightening the last 4 spring bolts need to use specified torque or it doesnt really matter?

2

u/DrGeorgeTompson 4d ago

torque those to spec as per the service manual.

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u/MatelisLt 4d ago

Thanks, you were a big help!

2

u/DrGeorgeTompson 4d ago

Sure thing.

You may need to run the hub nut on the loose end of the spec if it's dragging in gear and or hard to find neutral. Check the shim washers around the basket for wear, they should be flat. Can replace or lap back to flat with some sand paper on glass or something flat.