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Old 03-16-2013, 01:34 AM   #4
gefr
Life is a trip
 
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Joined: Nov 2005
Location: East Med, Greece
Oddometer: 3,805
I think you focused too much on bleeding the hydraulic clutch

I had huge clutch dragging problems when my bike was new. It was a Adv Dec 2003. My mechanic replaced the pushrod and installed the oil reduction jet. Nothing improved the situation. Finally the KTM moma stepped in after a complaint I did to them and they replaced the whole clutch assembly. I argued the oil reduction jet was installed after my clutch plates have been damaged. I never had the motor die though.
If you are sure you haven't misplaced the inner clutch disc with the larger inside diameter, where the belevil ring resides, I believe replacing your clutch assy would be the only option. However I cannot understand why you have so much drag to the extent your motor dies. That means you have no disengagement whatsoever. One surplus clutch disc maybe? 10 fibre and 11 steel IIRC.
How is the clutch feeling? Is it OK?
The pushropd pin is not binding the pushrod operation somehow?
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