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Old 02-10-2013, 10:23 AM   #1
ajvanderlee OP
distance rider
 
Joined: Oct 2010
Location: Austin, TX
Oddometer: 8
'03 640adventure clutch slipping in first

Ok, I just wanted to pick some brains on this one before I replace my clutch(only 12,000miles). My 640 clutch momentarily slips and then catches quickly only in first gear. Is this clutch failure(worn discs) or an adjustment only? More annoying them anything.
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Old 02-10-2013, 12:09 PM   #2
It'sNotTheBike
Banned
 
Joined: Jul 2011
Oddometer: 704
Are you using JASO-rated oil in the engine ?

Or are you using automotive oil ?

Oil engineered for cars doesn't work well with a wet motorcycle clutch and should
never be used in a motorcycle which has a wet clutch ( "wet" means the clutch
runs in a bath of oil which is shared with the gearbox and in the case of a 640, the
rest of the engine as well ).

Non-JASO oil can cause clutch slip.


Also, if your clutch master cylinder fluid reservoir is overfilled with mineral oil it can
prevent the clutch release mechanism from having the free play required to work
properly. Check your fluid level. You can remove a bit of fluid out of the reservoir
by dabbing a perfectly clean paper towel into the fluid. An overfilled reservoir
could cause clutch slip in pretty much any gear. It's worth taking five
minutes to check. Two Phillips-head screws attach the reservoir cover and
underneath that cover there is a rubber bellows which prevents the fluid from
"sloshing". Carefully lift the rubber bellows out to check the fluid level.


Here is a thread which deals with bleeding the clutch hydraulic system :

http://www.advrider.com/forums/showthread.php?t=348369


FInally, if none of the above possible causes applies in your case,
you could do worse than to remove the clutch cover and have a look.
If one or more of the fasteners which hold the clutch assembly to the clutch
hub are coming loose, your engine could be severely damaged by chunks of
metal if one of the fasteners breaks free and starts moving around inside the
engine. If it were my bike I would want to make sure this is not happening.



.

It'sNotTheBike screwed with this post 02-10-2013 at 01:30 PM
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Old 02-10-2013, 10:57 PM   #3
bmwktmbill
Traveler
 
Joined: Jul 2005
Location: Traveler
Oddometer: 4,942
Are you the original owner, has the clutch been apart?

In the shop manual are specific instructions for reassembly also the basket could be notched momentarily holding the plates apart.
bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
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