How To Install a Clutch Kit on a 2000 Husaberg FE600 Dirt Bike

How to Install a Clutch Kit on a 2000 Husaberg FE600

Why replace the clutch on a 2000 Husaberg FE600

The 2000 Husaberg FE600 is a 600cc fourstroke enduro machine that sees heavy-duty use steep technical trails, tight woods, sand and aggressive starts all stress the wet multiplate clutch. Replace the clutch when you notice slipping under load, dragging or incomplete disengagement, inconsistent lever feel, hard shifts, or when plates appear glazed. Proper replacement restores throttle response, reliable power transfer and crisp shift quality.

Clutch system overview what you're working with

• Type wet, multiplate clutch operated by a cable on the 2000 FE600.
• Common wear points friction plates, steel drive plates, clutch springs, basket fingers and hub splines.
• Symptoms to differentiate from cable issues if lever free play adjustment and cable inspection don't fix slipping or grabbing, the plates or springs are likely worn.

Prepare the bike

• Park the bike on a firm, level surface and secure it upright in a stand so the bike won't shift while you work.
• Clean around the clutch cover to prevent contamination when you open it.
• Because the FE600 uses a wet clutch, you'll usually need to drain or lower oil level when removing the cover catch oil in a suitable container for recycling and reuse or replacement.
• Have replacement plates presoaked in the correct engine oil for at least 15-30 minutes before assembly to prevent dry engagement.

Removing the clutch cover

Loosen the cover bolts in a crisscross pattern and remove the cover. Expect some oil to escape keep rags handy. Inspect the inside of the cover for metal particles or unusual debris that could indicate deeper engine wear.

Disassembling the clutch assembly

• With the cover off, back off any cable adjuster to remove tension from the clutch.
• Loosen and remove the clutch spring bolts evenly to avoid cocking the pressure plate. Remove the pressure plate and springs.
• Pull out the friction plates and steel drive plates, keeping them in order to note thickness and wear patterns.
• Inspect and set aside the thrust washer and pushrod (if present) verify they move freely and show no scoring or excessive wear.

Inspection checklist what to look for

• Friction plates look for glazing, burnt dark surfaces, excessive thinning or oil contamination beyond normal wear. Glazed plates will feel glassy rather than textured.
• Steel drive plates check for blue discoloration or warping that causes rough engagement or chatter.
• Clutch springs compare free length and resistance across springs; weakened springs contribute to slipping under heavy loads.
• Clutch basket & hub inspect basket fingers for notching or sharp grooves where plates engage; check inner hub splines for rounding or burrs that can cause drag or inconsistent engagement.
• Thrust washer & pushrod ensure surfaces are smooth and pushrod moves axially without binding.
• Oil condition if oil smells burnt or contains metal, replace it when reassembling.

Replacing components and preparing new plates

Use the new friction and steel plates from your clutch kit. Soak friction plates in fresh engine oil for the recommended soak time this reduces firstride slippage and ensures even breakin. Lay out parts in the intended installation order: friction, steel, friction, etc., matching the FE600's wet clutch alternating stack.

Reassembly plates, springs and pressure plate

• Install the clutch plates in the correct alternating order. Make sure each plate seats fully into the basket and hub splines without forcing.
• Reinstall the pressure plate and evenly snug the clutch spring bolts in a cross pattern to bring the plate up squarely. Tighten progressively to feel do not use excessive force; final torque should follow manufacturer guidance but is not listed here.
• Confirm the pushrod and thrust washer are positioned correctly and move freely when the lever is pulled.

Clutch cover, oil refill & cable adjustment

• Clean mating surfaces and reinstall the clutch cover with a new gasket or seal if required. Tighten bolts evenly in a cross pattern.
• Refill engine oil to the correct level with the appropriate specification oil for a wet clutch system fresh oil preserves clutch life and reduces noise.
• Since the FE600 uses a cable clutch, adjust cable free play at the lever so there's a small amount of free travel before engagement. Check the cable for binding or frays and lubricate where needed stretched or dragging cables often mimic clutch wear.

Hydraulic vs. cable reminders

On this model the cable clutch means lever feel can change with a sticky or stretched cable. If you ever encounter a hydraulic system on similar bikes, inspect the slave for leaks and air air in hydraulics will cause inconsistent engagement, but the FE600's cable system relies on clean routing and proper free play for consistent feel.

Final checks and breakin

• With the engine off, pull the clutch lever a few times to confirm smooth operation and correct free play.
• Start the bike and test engagement in neutral, then ride gently for the first few miles to allow plates to bed in avoid prolonged slipping or aggressive launches until the clutch has seated.
• Recheck oil level after the breakin run and inspect for leaks around the cover and cable connection.

When to return for deeper inspection

If slipping continues after new plates and fresh springs, recheck basket fingers and hub splines for notching or damage that can prevent full plate seating. Persistent hard shifting or chatter may indicate warped steels or other drivetrain issues requiring further teardown.

Closing notes

Installing a clutch kit on a 2000 Husaberg FE600 restores the direct, predictable power delivery that riders expect from a 600cc enduro bike. By cleaning the work area, inspecting basket and hub components, soaking friction plates, and properly adjusting the cable, you'll regain crisp engagement and reliable transfer of power for trail or enduro use.

Related Shopping Categories

Shop Clutch Kits for a 2000 HUSABERG FE600 Dirt Bike.

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Shop Clutch Springs for a 2000 HUSABERG FE600 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2000 HUSABERG FE600 Dirt Bike.

Shop Clutch Covers for a 2000 HUSABERG FE600 Dirt Bike.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.