Go Back   ADVrider > Bikes > Thumpers
User Name
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Thread Tools Search this Thread Display Modes
Old 02-10-2013, 09:23 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.
ajvanderlee is offline   Reply With Quote
Old 02-10-2013, 11:09 AM   #2
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 :

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 12:30 PM
It'sNotTheBike is offline   Reply With Quote
Old 02-10-2013, 09:57 PM   #3
Joined: Jul 2005
Location: Traveler
Oddometer: 5,218
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.
'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
bmwktmbill is offline   Reply With Quote


Thread Tools Search this Thread
Search this Thread:

Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump

Times are GMT -7.   It's 01:01 PM.

Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2015