No hole in clutch oil jet
 

My clutch has been feeling kind of sticky lately and I figured I would clean the clutch oil jet. I got it out and saw some muck in there tried to push it through and did not budge. All the oil and muck was cleaned out with carb cleaner. I looked into the hole and all I saw was clean brass that blocked the orifice. I tried pushing through with a tiny allen head head wrench and it just hits the solid brass "wall". No compresssed air goes through it as well. ???????

on a 2004 GO!!!!!:huh

On the early bikes like yours there was no hole in this, it is a blanking plug.
You can fit an oil jet as a mod.
Hope this helps. :wink:

So what's the use of the oil jet then?

It lubes the clutch actuator rod. The early bikes did not get enough oil through the case to stop them sticking AFAIK

Lubes the internal parts of the clutch, booster system.

.3 is standard KTM. We offer a modified .5mm for more oil flow and cooler clutch running.

More info here.

Might want to upgrade to the one piece pushrod too at that time.

Thanks! You're a great salesman may have to buy one :rofl

Early bikes had a plug in made of plastic.
 

Since yours is made of brass, I would think it has the tiny hole. However it seems yours is blocked. #30 is the original, not the same with 0.30mm. I would advise 0.50mm gives better results.

My 2011 was sealed as seen under my super duper Mr. Magoo Magnifying glass so I clamped her to the drill press and kept nudging the glob until the hole showed up. Cost me clutch in clay mud to discover it.

I had a .3 and wanted to get a .5
I took it to a watch maker and he drilled it for free !

My 03 950A had a solid brass plug:eek1. Bought ten 0.5 drill bits for $2 off eBay and wasted five of these trying to drill a hole in that sucker. So bought an 0.3 oil jet and had no trouble hand drilling to 0.5mm:D.

Can someone elaborate on this? What it's the pushrod's function? Is it what presses on/releases the clutch plates? And why go to a one-piece?

the 3 peice units have shown to collapse over time.

Are you not getting full release of your clutch system? This might be part of the problem.

A search might find old posts where this was found to be the issue.

Deadly99 was one if I recall.

If you have a spare case/engine, piston jet 0.6 works fine and same size OD

The three piece push rod did not have enough clearance, would rub and generate metal filings, and it would fall apart. The oil was supposed to travel down the center of the rod to oil the clutch.

The one piece is steel and a much smaller diameter. The oil flows on the outside. It doesn't fall apart or rub.

I've never heard of a plastic plug, the early ones had brass with no hole, then about early 2005 KTM put in an orifice. These need to be cleaned every 20k or so.

I suspect they have a grab-bin of jets... I have a 2011 Adv R and utterly no hole from new, an obvious cock up by the factory... Bored it out, but then eventually replaced it with a 0.50 from CJ - a very good mod with shifting