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BadTA 05-14-2013 12:49 PM

Clutch hard to turn
 
I am rebuilding my KTM 625 LC4 and am at the point where I am re-installing the clutch. I have put the clutch basket in and then the inner hub. At this point the inner hub turns freely. Now, when I tighten down the hex nut to the specified torque (60 ft.lbs.) the inner hub is now hard to turn.

Any thoughts?

Possu 05-14-2013 03:42 PM

Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?

shipwrek12001 05-14-2013 04:52 PM

Quote:

Originally Posted by Possu (Post 21409042)
Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?


:nod

assuming the clutch parts list is the same as the 640, #28 seems to the thrust washer. or lack of. if that is the case, you have tighten the basket on to the thrust brg #32 and now that would be damaged...

or not

BadTA 05-14-2013 08:30 PM

I can confirm that there is indeed a washer (#28) and it does exist in my installation.

Any other thoughts?

Captain115 05-15-2013 12:27 AM

Quote:

Originally Posted by BadTA (Post 21411055)
I can confirm that there is indeed a washer (#28) and it does exist in my installation.

Any other thoughts?

Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?

BadTA 05-15-2013 07:41 AM

Quote:

Originally Posted by Captain115 (Post 21411859)
Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?

That's correct.

BadTA 05-16-2013 09:10 PM

I'm running out of ideas here. The inner hub turns freely until I tighten down the hex nut, then it becomes difficult to turn. I have gone over the service manual and the micro fiche. I can't find anything obvious.

Please help.

Seikkailu_R 05-17-2013 09:05 AM

Old or new parts?

If old, check if there is any markings witch way thrust washer was installed before rebuild.

wrk2surf 05-17-2013 09:34 AM

with or without the O ring on the inside of the plates?

Seikkailu_R 05-17-2013 09:36 AM

Quote:

Originally Posted by wrk2surf (Post 21430182)
with or without the O ring on the inside of the plates?

No plates, only inner and outer basket.

BadTA 05-17-2013 11:28 AM

The washer is original and shows no real differences on either side.


http://img9.imageshack.us/img9/9799/...30517at124.png

http://imageshack.us/a/img43/738/scr...30517at107.png

http://img6.imageshack.us/img6/8979/...30517at115.png

This is what I am dealing with. The outer hub sits on the collar/needle bearing, then the washer, next the inner hub goes on and then the hex nut.

From what I can gather, tightening the hex nut pushes against the washer which pushes against the collar which pushes against the bearing in the case.

So, where is the binding happening?

Seikkailu_R 05-17-2013 11:48 AM

Check that collar/needle bearing/washer combo without any other parts, is there enought room for bearing.

Some times these washers can be installed both ways when new, but after some use only one way works.

And all parts on main shaft bearing are ok?

Can kickstarters idler gear installed wrong side out?

BadTA 05-17-2013 12:54 PM

I have checked the idler gear. I tried it both ways. I will try the install as you mention later today.

Thank you for your help!

BadTA 05-17-2013 06:00 PM

Some more pictures. The local shop thinks there is something wrong within the transmission. A washer out of place or something. If I put the collar/needle bearing on, and just the inner basket, I can tighten the hex nut and the hub spins happily. It is only when I include the outer hub.

http://imageshack.us/a/img211/1589/i...0517194628.jpg

http://imageshack.us/a/img96/8422/img20130517194735.jpg

Seikkailu_R 05-18-2013 06:38 AM

No washer after roller bearing?


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