Clutch Masters 02-06 Mini Cooper S 1.6L Supercharged FX200 Clutch Kit Sprung Disc

If your supercharged R53 Mini Cooper S has started to slip in the upper gears, smells hot after a spirited drive, or the old clutch is simply worn out at high mileage, the Clutch Masters FX200 kit (03050-HDKV-D) is a street upgrade that keeps the pedal and engagement close to stock. It is aimed at the 2002-2006 Cooper S owner with a pulley, intake, exhaust or tune who drives hard on the road but is not building a track car.

What the FX200 clutch kit does in a supercharged Cooper S

The 1.6L supercharged engine makes its torque low in the rev range, so the clutch is loaded hard every time you pull away or shift under throttle. The FX200 pairs the Clutch Masters Power Plus I heavy-duty pressure plate with a steel-backed Kevlar disc and a Marcel spring wafer under the lining. Clutch Masters rates it at 70 percent more holding capacity than stock. That is the same holding figure as its FX100 organic kit, but the maker says the Kevlar disc lasts two to three times longer, and the material is non-abrasive so it will not score the flywheel face.

Clutch Masters describes the FX200 as the smoothest stage it offers: only slightly more pedal pressure than stock and normal engagement and release. That makes it a good fit for a daily-driven Cooper S that sees stop-and-go traffic during the week and back roads on the weekend.

Symptoms that point to a worn or overmatched clutch

• Engine rpm rises with no extra speed in third, fourth or fifth at full throttle
• Slip that showed up after a smaller supercharger pulley or a tune
• Engagement point creeping toward the top of the pedal travel
• Burnt friction smell after a hill climb or hard launch
• Chatter or judder pulling away from a stop
• A whir or chirp that changes when you press the pedal, typical of a worn release bearing

How to confirm the clutch is the problem

Do a slip test: in fourth gear at about 2,000 rpm, roll into full throttle and watch the tach. If rpm climbs faster than road speed, the disc is not holding. Before buying, rule out the hydraulics by checking the fluid level, bleeding the system and making sure the pedal returns fully, and look for oil weeping at the bellhousing that can contaminate a disc. Our slipping diagnosis guide walks through the road test, and shift flare versus slip explains the difference between a momentary flare and a clutch that will not hold.

Fitment

Clutch Masters lists 03050-HDKV-D for the Mini Cooper S 2002-2006 with the 1.6L supercharged engine. It is not for the non-supercharged Cooper or the 2007-up turbocharged Cooper S, which use different clutch parts. If you have a later supercharged convertible or a John Cooper Works package car, send us your year and VIN before ordering.

The -D suffix matters. Clutch Masters builds this kit with a dampened (sprung) disc designed to be used with an aftermarket single-mass flywheel. If you are keeping the factory flywheel, the maker specifies the rigid-disc version, 03050-HDKV-R, instead. Match the full part number to your flywheel plan. Other Cooper S clutch options are in the rebuild kits collection.

What is in the box

• Power Plus I heavy-duty pressure plate
• Heavy-duty sprung-hub disc with steel-backed Kevlar lining
• Release bearing, plus pilot bearing where the application uses one
• Alignment tool and instruction card

The flywheel is not included.

Install notes

• Fit the single-mass flywheel first, torqued in a cross pattern, and clean the friction face with brake cleaner. The ACT 600315 Streetlite chromoly flywheel is a single-mass option built for the supercharged Cooper S; confirm compatibility with us before mixing brands.
• Center the disc with the supplied alignment tool, then draw the pressure plate bolts down a little at a time in a star pattern so the cover seats evenly.
• Inspect the release fork, pivot and slave cylinder while the gearbox is out, and grease the input shaft splines lightly.
• Bleed the clutch hydraulics with the brake fluid grade printed on the reservoir cap.
• Drive gently for the first few hundred miles, with no launches or full-throttle shifts, so the disc and flywheel bed in.

Need more holding power for a heavily modified car? The FX300 version of this kit raises holding capacity to 110 percent over stock with a segmented Kevlar disc.

Will this fit my 2007 Mini Cooper S?

Clutch Masters lists 03050-HDKV-D for the 2002-2006 Cooper S with the 1.6L supercharged engine. The 2007-up turbocharged Cooper S hatch uses different parts. If your car is a later supercharged convertible, send us the year and VIN so we can check it.

Can I use this kit with my factory flywheel?

Clutch Masters designs the -D dampened disc for an aftermarket single-mass flywheel. For the factory flywheel the maker specifies the rigid-disc kit, 03050-HDKV-R. Order the version that matches the flywheel you will run.

How does the FX200 compare to the FX100 and FX300?

The FX200 holds the same 70 percent over stock as the FX100, but its Kevlar disc lasts two to three times longer according to Clutch Masters. The FX300 uses a segmented Kevlar disc for 110 percent more holding and is meant for heavily tuned or higher-boost cars.

Will the pedal be much heavier than stock?

No. Clutch Masters says the FX200 has only slightly increased pedal pressure and normal engagement and release, the smoothest of its stages.

What should I replace at the same time?

The flywheel, since this kit needs a single-mass unit, plus the rear main seal if it is weeping. Check the slave cylinder and release fork while the gearbox is out, and bleed the system with the fluid grade on the reservoir cap.

• How to Diagnose Transmission Slipping
• Shift Flare vs. Slip: How to Tell Them Apart
• Automatic vs. Manual Transmission Repair Cost