Best clutch for big HP and the differences of them all

I know you can change springs, fibers, steels, lock out.

 

What are all the differences and who has pics to compare. Such as clutch spring difference and clutch difference all together. Maybe a good write up on how to properly replace your clutch fibers with pics

I'll be putting in my tusk clutch today. I'll take pictures of the step by step. Glad I found this so early in the morning. Now I can feel like I am actually helping and not taking up space on the site... lol :gr_cheers:

Here are some pictures I've taken and labeled over the years:

http://www.offtopic.forum/uploads/imported/2012/04/clutch_1-1.jpg

 

http://www.offtopic.forum/uploads/imported/2012/04/clutch_2-1.jpg

 

http://www.offtopic.forum/uploads/imported/2012/04/clutch_3-1.jpg

 

http://www.offtopic.forum/uploads/imported/2012/04/clutch_4-1.jpg

 

http://www.offtopic.forum/uploads/imported/2012/04/clutch_5-1.jpg

 

Current clutch I'm running...with Dark Synergy MOD Springs:

http://www.offtopic.forum/uploads/imported/2012/04/clutch_6-1.jpg

 

The only oil I will use in my transmission:

http://www.offtopic.forum/uploads/imported/2012/04/clutch_7-1.jpg

 

My full tech article write-up with part numbers, etc:

http://webpages.shepherd.edu/ghott01/punisher/clutch.html

excellent comparison picture of the springs ghott.

why is the dark synergy springs so much longer? seems you wouldnt be able to dis engage the clutch very well? or does the longer spring just put more constant pressure when the clutch is fully engaged?

what are the ups and downs to all these springs? lets hear some tech

I wrote this up a good while ago for my personal site. Take the info for what you will. I added some updates to this as well.

 

This information was gathered by a lot of members on various forums so I'd like to give credit where credit is due...Dustin (Blackie) @ EKO Racing, Brian (wppracing) @ WPP Racing, Morgan (DemonIndustries) @ Demon Industries, Michele (quadmom) @ RAGE ATV Racing, Corey (#8TRX450R) @ ATV Tech, Gerry (El Duner) @ ATV Tech, and Mark (mwsartain) @ TRX450R.org.

 

Part numbers:

Standard CR500R - 22401-ML3-910

Taller CR500R - 22401-KA5-740

Standard 250R - 22401-HA2-670

HD 250R - 22401-HB9-770

CRF450R - 22401-KZ3-690

 

Where to buy?

- TUSK brand springs - Rocky Mountain ATV MC web site.

- OEM springs - Service Honda web site using the part numbers supplied.

- Dark Synergy springs - They have now been rebranded several times...performance spring, and have now been bought out by Tokyo Mods (so I hear).

 

Dark Synergy Springs

Verbiage taken from Dark Synergy's old web site: Operating Range over 200 degrees F higher than the best OEM clutch springs. Engineered with the lowest possible spring rate for a smooth pull and positive engagement, and with the precise installed pressure needed to ensure minimal clutch slippage. Extends clutch life and Improves clutch performance. No more clutch fade! Outperforms OEM and aftermarket clutch springs. Lifetime warranty!

 

...FYI, Dark Synergy changed their name to "Performance Spring." I've heard that they no longer make ATV Clutch Springs...and their remaining stock was sold to Tokyo Mods. I had also heard that the DS "MOD" springs were actually DS LTR-450 springs. However, I ordered a set of Tokyo Mods LTR-450 clutch springs and they were not the DS "MOD" springs...they were much shorter...and I'm not even sure if they have the same heat resistant coating, etc.

 

HD 250R Springs

I've heard mixed reviews on the HD 250R clutch springs...some have said they cause coil bind and need to be modified to fit...others say they are a drop in spring...but everyone has said you're left forearm will look like Popeye's after using them for a while. I wouldn't recommend using the HD 250R clutch springs unless you have a lockout.

 

My Clutch Setup & Experience

Currently, I'm using an OEM '06 CRF450R clutch in my bike along with the High HP (MOD) Dark Synergy clutch springs. The CRF clutch was recommended to me by RAGE. Michele told me that the CRF clutches have a thicker inner and outer fiber and they hold up well on their builds...and we all know RAGE can build some power. Note: there is no judder spring in the CRF kit. I purchased the CRF clutch kit on eBay for $135 with shipping (also available at Service Honda) and the High HP Dark Synergy springs were $60 with shipping. I've gone through one OEM TRX450R clutch and two Tusk clutches in my bike, so paying a little more money for a setup that should last was definitely worth it to me. 95% of the riding I do is on pavement where there is a constant load on the bike. The CRF clutch with High HP DS springs seems to be holding up well with my mid 50's HP stock bore/stroke build.

 

^^^Update on the paragraph above...after 3 years of abuse (didn't ride all that often, but thrashed it pretty hard when I did), the CRF clutch fibers and plates were smoked...clutch basket is also notched. A brand new OEM CRF450R clutch will be going back in it, along with a Wiseco Forged clutch basket...and I haven't decided if I should keep the old DS MOD springs that are 3 years old, or go with the newer Tokyo Mods LTR-450 clutch springs that I had ordered (shorter than the MOD springs).

 

My Dad is using a RMATV TUSK clutch in his bike with the Standard Dark Synergy springs. His clutch is a bit easier to pull and has been holding up well with his build (mid-high 40's HP stock bore/stroke).

 

We run red bottle Honda HP 80/85W transmission oil in both bikes.

 

CRF Clutch Part Numbers:

Below are the part numbers for the OEM 2006 CRF450R Clutch. The clutch kit (06001-MEN-001) comes with everything needed. I provided the part numbers for everything that is contained within the clutch kit in case anyone wanted to buy the parts separately.

 

OEM CRF Clutch and Parts

Part Description Part Number

(1) 2006 OEM CRF Cutch Kit 06001-MEN-001

(6) Clutch Springs 22401-KZ3-690

(8) Clutch Friction Disks 22201-MEB-670

(7) Clutch Plate B 22321-KZ3-690

(1) Clutch Cover Gasket 11352-MEB-671

I agree with Ghott,

 

Dark synergy HD springs with a good OEM clutch seemed to last well on my old bike. Anything north of 40 ft lbs would probably be smart to have a lockout.

I also have had good success with an OEM clutch and the high HP DS/PSI/Tokyo Mods springs. That setup will hold a lot of power.

Oh man, I did a full write-up about a year ago on the old 450rtech.com site.

I think it's all gone right now though.

 

Heres the difference in the stock plates on my old 05 compared to Barnett Dirt Digger clutch

http://www.offtopic.forum/uploads/imported/2012/05/sspx0297-1.jpg

 

 

The longer spring is the Barnett spring

http://www.offtopic.forum/uploads/imported/2012/05/sspx0292-1.jpg

i've been running the barnnett dirt digger with their HD springs for years now. with lots of drag racing. no slipping.

Glad this thread got brought up just ordered a DD lockout and needed the crf clutch part #s. Anyone with experience with the lockout have any tips with tuning it ? I read on their sight you can tune it with springs and moving the weights on the fingers. I would like to set it up with a little slippage on takeoff then full lock.

i have also noticed that some of these springs are made of differant diameter material so that would tell me that even thow its shorter it could still have a higher spring rate i was just woundering if anyone has ever checked or if someone could check the spring rates

I have a spring tester used for valve springs. I have used it to compare clutch springs in the past and it worked great. Any of the engine guys can do it.

I also have had good success with an OEM clutch and the high HP DS/PSI/Tokyo Mods springs. That setup will hold a lot of power.

 

^^ Agreed ^^ It doesn't get much better than this setup. :thumb:

 

 

i have also noticed that some of these springs are made of differant diameter material so that would tell me that even thow its shorter it could still have a higher spring rate i was just woundering if anyone has ever checked or if someone could check the spring rates

 

Spring rates do play a factor, but the material used to make the spring is more important. Dark Synergy used steel that would, with stand the extreme heat these clutches produce. All others do fail in time.