I'm currently travelling trough South America on a DR650SE from 2000 and at 65000km the clutch started slipping at full throttle in fifth gear. After reading all the forums I decided to put a washer behind the clutch springs in order to give it a bit more length but they are still in spec at 34.2mm, so with a 1 mm washer it should be sufficient right?
This didn't helped and eventually started slipping in fourth gear as well. So I decided to fly in the metal discs and friction plates from Peru as there are no parts in Bolivia. I've measured all the old plates and discs and where 2,9 - 3,0. Also in spec. The metal discs weren't burned but the plates and the discs are a bit warped.
I checked the washer and bushing behind the basket and these show some wear but nothing shocking. I filed down all the grooves in the inner basket as well. So I decided to put everything back together with the new plates, discs and the 1 mm washers behind the springs, fresh motul semi synthetic 15w50 (only motorcycle oil available here). The first test ride was horrible. It slipped in all the gears. I adjusted the cable all the way but no difference...
So I took it apart again and then I found out that the circlip had broken and was mangled between the first metal disc and friction plate and had completely stripped of the friction material. So that explained the slipping. As I don't have any other plates and don't want to pay another 250usd for shipping and import tax i decided to put the most straight and thick friction plate in there from the old clutch.
I put it in as the first friction plate (e.g. The closest to the engine) because as far as I know are the plates which are the furthest away from the engine the ones which gets the most stressed and worn out the quickest, or am I wrong here?
Anyhow confident it would be solved I put everything back together again to only found out it slips at full throttle in fifth gear again...
Does anybody has an idea what to do?