Clutch Assembly

mike.l · 01-02-2013, 03:20 AM

After some amount of hassle with the clutch on my '05 950 Adv, I discovered that the previous owner hadn't lined up the dots on the clutch pressure booster when re-assembling the clutch... new parts have been ordered!

Q. Do I use a clutch basket locking tool when re-assembling the clutch or as someone suggested, a special pin
that goes into the crank?

StevenD · 01-02-2013, 03:26 AM

pin wont do you any good as the gears side will spin with the inner clutch cage. A strong foot on the rear brake works for me, or the clutch holder.
The pin only works with a ktm special tool holding the inner and outer basket together.

mike.l · 01-02-2013, 11:52 AM

Is that the same Clutch holder that's in the workshop manual's 'special tools' drawing? Part no 600.29.003.000.
I want to be able to tighten all the clutch up again once it's re-assembled. I'm a beginner here, there are no KTM dealers/workshops where I live, so I'll have a go. Anything else I need to know about?

HellsAlien · 01-02-2013, 04:30 PM

Check your hex socket chamfer on the inside leading edge. If its too big you will have minimal engagement with the thin nut, which can lead to slip/strip on the nut. One solution is to grind the socket back to get sufficient engagement.

rossguzzi · 01-02-2013, 11:06 PM

I had trouble getting the clutch inner nut off. Even with the air impact driver. Didnt do it for too long as I thought it would have just come right off.
What am I doing wrong?

01-02-2013, 03:20 AM	#1
mike.l ^OP Adventurer Joined: Jan 2012 Location: Mid West Ireland Oddometer: 54	Clutch Assembly After some amount of hassle with the clutch on my '05 950 Adv, I discovered that the previous owner hadn't lined up the dots on the clutch pressure booster when re-assembling the clutch... new parts have been ordered! Q. Do I use a clutch basket locking tool when re-assembling the clutch or as someone suggested, a special pin that goes into the crank?

01-02-2013, 03:26 AM	#2
StevenD Hmmmm, dirt! Joined: Aug 2005 Location: Holland, Amserdammed Oddometer: 892	pin wont do you any good as the gears side will spin with the inner clutch cage. A strong foot on the rear brake works for me, or the clutch holder. The pin only works with a ktm special tool holding the inner and outer basket together. __________________ 950 Rally custom - 690 Enduro Ride ON!

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01-02-2013, 11:52 AM	#3
mike.l ^OP Adventurer Joined: Jan 2012 Location: Mid West Ireland Oddometer: 54	Is that the same Clutch holder that's in the workshop manual's 'special tools' drawing? Part no 600.29.003.000. I want to be able to tighten all the clutch up again once it's re-assembled. I'm a beginner here, there are no KTM dealers/workshops where I live, so I'll have a go. Anything else I need to know about?

01-02-2013, 11:06 PM	#5
rossguzzi Gnarly Adventurer Joined: Oct 2012 Location: Bottom left hand side of OZ Oddometer: 243	I had trouble getting the clutch inner nut off. Even with the air impact driver. Didnt do it for too long as I thought it would have just come right off. What am I doing wrong?