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Old 03-22-2008, 06:17 PM   #90
Orange Caveman
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Joined: Nov 2004
Location: masa yee yah tee 59 14' 9" N / 135 26' 42" W
Oddometer: 7,103

Originally Posted by MrH
Like others above, I've an 03 model., and after reading this thread had a look at the Oil Reduction Jet the other day and - mine's never been done either, there's a brass plug, no jet.

Now on the one hand I'm pissed off that the dealer I bought it from (Premier in Didcot) told me all required updates had been done, but on the other there's nothing noticeably wrong with the clutch after 32k miles, so I can't exactly complain, can I?

The Repair Manual I've got is the 03 one, and the lubrication diagram in there doesn't show any oil going to the clutch at all, or the pushrod, just 'Another oil duct leads to the oil line that lubricates the transmission gears.'

I find it hard to believe that the clutch itself gets all it's oil through a 0.3mm hole? If I've still got the brass plug in instead of the jet, does that mean my clutch doesn't get any oil? So what is this jet supposed to fix?
The clutch gets lubed with oil from the transmission via the mainshaft and countershaft roller bearings and to a degree from oil thrown off the counter balancer gear and pinion gear. The clutch also runs in whatever oil is pooled in the sump.

Originally, apparently it was decided that that was enough oil for the clutch for its intended use. After the first season of racing, it was obvious that it was not enough for racing conditions. The Rallye bikes were having clutch problems. Amongst other things, Feliciani (Meoni's mech) and others were putting larger and larger jets inplace of the plug to help lube the clutch better from the inside (via the pushrod passage).

In July of 2003, KTM started installing a small jet .30mm. This was supposed to be retrofitted to all previous models in a Tech Bulletin (0309/38/01-E) issued in September of that year

The engineers were reluctant to install an oil jet at first, but they allowed for one in the design. As stated earlier, too much oil to the clutch causes problems also.


DISCLAIMER: All observations made in this post are mine and based solely on my own anecdotal experiences, and may contain large doses of facetiousness. YMMV, of course. You are "on your own", and I take no responsibility if someone tries anything in this post and gets into trouble with the law, damages their person or property, or goes blind. Take everything you read or hear "anywhere" butt especially on the Web with a large dose of salt.

cpmodem screwed with this post 03-22-2008 at 06:49 PM
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