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Old 03-26-2013, 03:41 PM   #1
MAXVERT OP
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Location: Sun Valley Idaho
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Inner Clutch Hub Excessive Play ?

I'm in the process of going through my '07 990 A in preparation for
riding the TCAT.
The bike at present has 32,000 mi. with no problems and has been ridden like a KTM should be ridden.

The inner clutch hub ( basket ) has some side to side and in and out free play. Maybe 2 mm.
The 22mm. nut that holds it on sits just proud of the threaded shaft.
Around 1 to 2 mm. though the nuts inner edge has a slight bevel which
flushes out with the shafts face.

The inner and outer clutch baskets show no excessive wear, same with the clutch booster assembly.

Would you say this is an acceptable amount of movement ?

I've tried to take the nut off with a impact wrench but couldn't
break it loose.

Would someone have a suggestion for keeping the inner hub from moving while trying to loosen the nut with a bigger bar.
Or should I heat it first.

Thanks, Max
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Old 03-27-2013, 01:30 AM   #2
uk_mouse
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I seem to remember this being a problem reported before. There shouldn't be any in-out movement on the centre basket.

The best way to remove the nut is to lock the two baskets together with the special tool - or to make your own tool by sacrificing two clutch plates. Get one steel plate and one friction plate, and bolt them together (in the position they would be in when fitted).

If there's loctite on the nut, then certainly a bit of heat will help it break free.
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Old 03-27-2013, 10:53 AM   #3
RedRupert
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You can hold the shaft by applying the rear brake, when in gear. You could also block the rear brake by inserting a soft metal (aluminium or copper) bar through one of the holes in the disc. Don't be tempted to use hard metal, as it will damage the disc.

Still you need to be careful. I use the proper KTM holder, but UK's method is equally as effective.

You need to apply plenty of force. I use a 2' bar.

How you describe the 32mm nut is normal.

Also, if the clutch functions OK, the booster is probably OK.

The play that you describe re the baskets is also normal. I replaced the needle bearing when my 2004 950 was new-ish, but it made no difference. My new 990 motor is the same.

I don't like it, but I've got used to it. It's all been noisy but OK for 60,000+ miles.
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Old 03-27-2013, 12:38 PM   #4
Yardstick
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1-2mm seems like a lot, but if you aren't getting any strange noises or vibration it is probably okay. I replaced the bearing when I found play in my clutch basket, but I don't think it was necessary. Here's the thread where I asked a similar question.
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Old 03-28-2013, 08:56 AM   #5
Dusty
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Did that cure the wobble you had, when you replaced the bearing?

I saw same on my basket last year while doing winter maintenance.

edit; Just read the thread again and i see that it didnt.
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Old 03-28-2013, 03:23 PM   #6
MAXVERT OP
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Quote:
Originally Posted by Yardstick View Post
1-2mm seems like a lot, but if you aren't getting any strange noises or vibration it is probably okay. I replaced the bearing when I found play in my clutch basket, but I don't think it was necessary. Here's the thread where I asked a similar question.
I read that thanks.
My clutch baskets show less wear than yours in the fotos and
the movement was only in the inner basket.
So I measured the metal and fiber clutch plates, the spring hieghts.
Everything was well within spec and I put it back together.
Well see if it lasts for the 15,000 miles I'll need to ride to do the TCAT.

Twist it, Max
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