How To Install a Clutch Kit on a 2000 Husaberg FXE600

Shop parts for a 2000 Husaberg FXE600 Dirt Bike.

Why replace the clutch on your 2000 Husaberg FXE600

The FXE600 is a big-displacement enduro/dual-sport machine hard launches, creek crossings and tight woods riding stress the clutch. Common signs a replacement is due include slipping under load, dragging or poor engagement, inconsistent lever feel, hard or crunchy shifting and reduced throttle response. Replacing worn plates and springs restores power transfer, crisp engagement and consistent lever travel so the bike responds predictably on technical trails or aggressive starts.

Understand the FXE600 clutch system

The 2000 Husaberg FXE600 uses a wet, multi-plate clutch with a cable-operated release. That means the clutch pack runs in engine oil and the release is controlled by a mechanical cable inspect both the plates and cable when symptoms appear. Cable slack or binding can mimic worn plates, while oil condition and heat influence plate life on a large-displacement END/dual-sport like the FXE600.

Tools & prep

  • Basic hand tools sockets, ratchet, metric wrenches, clutch holding tool or makeshift holder
  • Clean rags, drain pan, small brush, pick or screwdriver
  • New clutch kit (friction plates, steels, springs, thrust washer if included)
  • Fresh engine oil and filter if you drain the crankcase
  • Platform or stand to keep the bike upright and stable

Prepare the bike

  • Place the FXE600 on a stable stand with the engine level.
  • Warm the engine slightly then shut it off warm oil drains easier if you choose to remove oil.
  • Drain oil if the clutch cover requires oil removal for access. If the clutch cover is above the oil level you may be able to change plates without full oil removal still work cleanly to avoid contamination.
  • Disconnect the clutch cable at the lever to relieve tension and allow full release.

Remove the clutch cover

Clean the area around the clutch cover to keep debris out. Remove cover bolts in a crisscross sequence to avoid distorting the cover. Carefully pull the cover free some o-rings or gaskets stick, so pry gently and keep a rag beneath to catch any residual oil.

Disassemble the clutch pack

  • Loosen the clutch spring bolts gradually and evenly, removing springs and pressure plate. Keep springs and bolts in order so you can reuse them with even seating.
  • Remove the pressure plate and lift out friction and steel plates one at a time, noting the order and orientation. On the FXE600 you'll typically alternate friction then steel.
  • Inspect the clutch hub, basket and inner splines as you remove plates.

Inspection checklist what to look for

  • Friction plates check for glazing, thinning, hardened edges or uneven wear. Slight burnishing is normal; deep glazing or oil-soaked soft material indicates replacement.
  • Steel plates look for discoloration (blueing), heat spots or warping. Replace any steel that shows heat damage or is visibly bowed.
  • Clutch basket & hub inspect basket fingers for notching or hooked grooves where plates engage; check hub splines for rounding or burrs.
  • Springs compare free length to the old set across all springs. Weak or uneven springs cause inconsistent engagement; replace springs in sets.
  • Thrust washer & pushrod check for wear or scoring; ensure the pushrod moves freely without excessive play.
  • Oil condition dark, contaminated oil accelerates wear on a wet clutch. Note oil color and debris; plan to replace oil.

Prepare new plates

Soak new friction plates in clean engine oil for at least 15-30 minutes so they are fully saturated before assembly. This reduces initial slip and bedding time. Wipe steel plates clean and inspect for burrs.

Reassemble the clutch pack

  • Install plates in the correct sequence typically friction plate, steel plate, repeating until the pack is complete. Ensure each plate seats fully into the basket grooves and engages the hub splines without forcing.
  • Install the pressure plate and position springs. Tighten spring bolts evenly in a cross pattern to seat the pressure plate squarely. Do not overtighten; snug them progressively so the plate compresses evenly.
  • Before tightening fully, check that the pushrod and thrust surfaces are clean and aligned so the release acts smoothly.

Reinstall the clutch cover and finish-up

  • Clean the mating surfaces and install a new gasket or o-ring if applicable. Bolt the clutch cover back in place in a crisscross pattern to seat the cover evenly.
  • Refill engine oil if you drained it. Use the oil weight and type suited to the FXE600's wet clutch environment; proper oil choice helps clutch longevity.
  • Refill engine oil if you drained it. Use the oil weight and type suited to the FXE600's wet clutch environment; proper oil choice helps clutch longevity.
  • Reconnect the clutch cable. Adjust free play at the lever so there is a small amount of slack before the clutch begins to disengage avoid a too-tight cable, which can cause drag, or too loose, which causes premature slip.
  • For a cable-clutch: check the cable routing for smooth bends and no binding. Lubricate the cable if worn or sticky.

Check operation & break-in

With the engine off, pull the lever and verify full movement and smooth return. Start the bike, let it warm briefly, and test clutch engagement in a low-traffic area: shift through the gears, check for chatter, slipping or dragging. New plates may feel slightly different at first gentle use and a few heat cycles help the clutch bed in. Re-check cable free play and any fasteners after the first ride.

Notes on wear patterns and riding context

On a 600cc enduro like the FXE600, aggressive starts, sand riding and heavy clutch slipping in technical terrain accelerate plate wear. Overheating from repeated slipping leads to steel discoloration and friction glazing. Regular oil changes and attention to cable adjustment prolong clutch life and maintain crisp throttle response.

Final tips

  • Keep parts organized during disassembly to preserve correct order and orientation.
  • Replace springs and heavily worn steels together for balanced engagement.
  • Address cable stretch early a binding or slack cable can be mistaken for a failing clutch pack.
  • After service, confirm no external oil leaks and that engagement is consistent across the lever travel.

Related Shopping Categories

Shop Clutch Kits for a 2000 Husaberg FXE600 Dirt Bike.

Shop Clutch Baskets for a 2000 Husaberg FXE600 Dirt Bike.

Shop Clutch Springs for a 2000 Husaberg FXE600 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2000 Husaberg FXE600 Dirt Bike.

Shop Clutch Covers for a 2000 Husaberg FXE600 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.