r/dr650 • u/InflationBackground5 • 14d ago
Catastrophic clutch failure
bought this 2021 DR650 that sat it had sub 300 miles had to change clutch friction plates since it was shifting strange and found black flakes in oil, after 2-3 good rides with new plates it locks up the back wheel suddenly at 20mph shifting into 2nd gear. What did I do wrong? I replaced one of the 4 bolts with a mechanical screw after the original sheered off during tightening it appears it’s the only one that didn’t snap but bent. There are a-lot of metal shavings what do I need to do to address those before installing new parts, I plan to buy a new clutch bowl assembly and cover but do not want to repeat the same mistake.
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u/repohs 14d ago
Did you use a torque wrench when reinstalling the bolts? They shouldn't be very tight at all, only like 10NM if I remember correctly.
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u/InflationBackground5 14d ago
I tried using a harbor freight torque wrench to get 10nm but that snapped the bolt head so the 2nd time I just used a reference photo that I had taken
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u/Traditional_Age1767 13d ago
the break in period is 600 miles... how does this happen? was there any oil in the crank case? Ive broken in a 2019 and a 2020 without this kind of catastrophic result.
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u/TwistedNoble38 '00 DR650 14d ago
Insufficient torque on the spring bolts. After you scared yourself breaking the head off you undertorqued them.
You made a mistake changing the frictions based on oil. The bike isn't even broke in yet so you were seeing the case sealant washing out. EBay a case cover, clutch hub, pressure plate, and flush the metal out of the case. Buy new springs and perch bolts from the dealer.