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Old 04-08-2013, 01:48 PM   #1
Unruled OP
950S
 
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Joined: Sep 2012
Location: Drugs, wooden shoes and windmills
Oddometer: 106
Clutch troubles

Hi guys,

I've had a 950S for a while now (2003, first European year) and am quite content indeed. It does have one small issue though, being the clutch. I know that KTM threw a wobbly when they designed the thing, and it's a weak spot. But I can't seem to find exactly where the problem is located and what's needed to fix it. I need the bike every day and can't (time-wise) afford to take it apart, assess damage, put back together and fix some other time.

Symptoms are limited to a very snappy clutch when the engine is cold. There is no vague feel (slave has already been replaced... by new original unit, but functions fine) and it completely disengages, doesn't slip when engaged.

However, when riding away with a cold engine I have to feather the throttle and ease the clutch out carefully, otherwise it lashes back, whips the chain rather uncomfortably (chain tension is set correctly) and I'll be lucky if the engine doesn't stall in the process (northern Europe, it's around freezing point here in the mornings, so cold means cold). Problem seems to be getting worse the past 2,000km (1,200mls).

Is the unit completely shot or is it a simple fix? Haven't checked the oil jet yet, but surely it can't be just that...
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Old 04-08-2013, 02:31 PM   #2
gefr
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It could be oil reduction jet.

Also the central nut being loose and/ot the deeper steel disc having a groove developed from friction to the belevil spring. I suggest you check all these. Not too much time needed. 1/2 an hour if you do not get you hands dirty(using gloves) or another 10' for washing hands. Cheers.
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Old 04-08-2013, 04:29 PM   #3
dogsslober
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Check the the booster to
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Old 04-08-2013, 09:12 PM   #4
keener
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Quote:
Originally Posted by gefr View Post
Also the central nut being loose and/ot the deeper steel disc having a groove developed from friction to the belevil spring. I suggest you check all these. Not too much time needed. 1/2 an hour if you do not get you hands dirty(using gloves) or another 10' for washing hands. Cheers.
Not hi jacking the thread, this will help the OP too:

I have exact problem as the OP but it does not happen on every cold morning. Its sporadic.

The other day, I took the clutch cover off, took all the plates off and measures the pack. It was within spec as 50.50mm so as all the disks and plates. Springs were just above the spec at 29.45mm. BUT the last disk had the groove you are talking about. I can't see how the groove can't happen! That disk is right against the spring washer.

How does this groove can cause snappy clutch with cold oil?! I'm puzzled and very curious.

ATT OP: This was a 30 min job. No oil lose with bike on side stand. I put couple pieces of plywood under the rear tire just in case. Keep in mind you have to torque 6 bolts holding the springs to 10nm which is critical as far as I know.
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Old 04-08-2013, 10:55 PM   #5
Unruled OP
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Thanks guys, going to look into that. Is the clutch seal going to fail or can it be reused? Still have to figure out where to easily order that stuff over here...

I can understand why that groove might be a problem, but also not quite sure why the problems would fade when hot? I'll also have to figure out how the booster works, previous bike didn't have one :P
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Old 04-08-2013, 11:08 PM   #6
gefr
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The booster has these ramps that push to each other as the clutch tries to slip

The one part climbs on the other and they lock causing higher pressure to the clutch discs against the pressure plate.
The grove reduces the force from the belevil spring, because it loses some tenths of a mm, as it rests in the groove. So its function unsticking the clutch discs is compromised. The grooved disc needs to be replaced with another one.
Cheers.
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Old 04-09-2013, 01:07 AM   #7
jfh
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Clutch

Hello Unruled,
you describe the symptoms well in your post. I've had similar for some 4000 miles. When I clean the clutch oil jet the symptoms disappear only to return gradually (or am I being more careful when warming up - as you say clutch works fine when hot).
How many miles has your bike done? Mines an 05 Adv on 30000+. Orig clutch.
Has anyone taken out the clutch booster and reprofiled the ramps with a file or grinder?
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