Clutch Friction Plate Alternatives (Kevlar)

25 Apr 2016

The Tornado requires 10 friction plates, and the total stack, including steel plates must measure between 48 and 50 mm. Less than 48 and the clutch will slip, greater than 50 and the last plates, steel or friction could disengage from their carriers.

Manufacturers

Surflex p/n: FSRS2188
Barnet 301-35-10012 (sold separately)
 [old part numbers for sets:- HPK-39A (7x), HPK-39D (7x), HPK-68D (8x), HPK-80D (8x), HPK-43D (7x)]

Bikes That Use The Same friction Plates

 (From the Barnett website)
 (Bear in mind that the Tornado friction plates are not cork, so the plates from the following bikes may not be suitable.)

Honda CR250R 1983-1989 (7); 1990-2007 (8)
CR480R 1983 (7)
CR500R 1984-1989 (7); 1990-2001 (8)
CRF450R 2002-2011 (requires 8, also requires 1 of 301-35-10013 for 2011 models)
CRF450X 2005-2009 (8)
NX650 1988-1989 (7)
TRX450ER 2004-2009 (7)
TRX450R 2004-2009 (7)
TRX700XX 2009 (7)
XL600R 1983-1987 (7)
XR500R 1983-1984 (7)
XR600R 1985-2001 (7)
XR650L 1985-2009 (7)
Husqvarna SM610 2006-2008 (8)
SMR450 2008 (8)
SMR510 2008 (8)
TC450 2008 (8)
TC510 2008 (8)
TE450 2008 (8)
TE510 2008 (8)
TE610 2006-2008 (8)
TXC450 2008 (8)
TXC510 2008 (8)
WR250 2006-2008 (8)
Kawasaki KFX400 2003-2004 (requires 7, also requires 1 of 301-35-10013)
KFX400 2005-2006 (requires 8, also requires 1 of 301-35-10013)
KFX450R 2008-2011 (requires 7, also requires 1 of 301-35-10013)
KLX400 2003-2004 (requires 7, also requires 1 of 301-35-10013)
KLX450R 2008-2009 (8)
KX450F 2006-2011 (8)
NINJA 250R 2008-2011 (5)
Polaris OUTLAW 500 2006-2007 (requires 7, also requires 1 of 301-35-10013)
PREDATOR 500 2003-2007 (requires 7, also requires 1 of 301-35-10013)
Suzuki DL650 V-STROM 2004-2011 (requires 6, also requires 1 of 301-35-10013)
DR-Z400 2000-2011 (requires 7, also requires 1 of 301-35-10013)
EIGER 400 4x4 2002-2007 (6)
LT-Z400 2003-2004 (requires 7, also requires 1 of 301-35-100130); 2005-2009 (requires 8, also requires 1 of 301-35-10013)
QUADRUNNER 500 (LT-F500F) 1998-2007 (6)
SV650 2003-2009 (requires 6, also requires 1 of 301-35-10013)
TL1000R 2001-2003 (9)

 Friction Plate Sources

Source 1 - Motorcycle Products Ltd p/n: VP1054 3.00 mm (suggested by colintornado, Benelliforum)
Source 2 - Carpi Moto s.r.l., Genova - Italy, p/n: FSRS2188, manufactured by Surflex (suggested by stevet547, Benelliforum)

Steel Plates

There are several Japanese bikes with plates that have the same outside and inside dimensions, but none have been found (so far) that match the carrier spline.

 Steel Plate Sources

Maniac Motors can supply 2.0 mm and 2.5 mm thick plates.

Pusher Plate

After 100,000 kms of normal use, expect the pusher plate to be worn ~ 0.2 mm.