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Old 05-14-2013, 01:49 PM   #1
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Clutch hard to turn

I am rebuilding my KTM 625 LC4 and am at the point where I am re-installing the clutch. I have put the clutch basket in and then the inner hub. At this point the inner hub turns freely. Now, when I tighten down the hex nut to the specified torque (60 ft.lbs.) the inner hub is now hard to turn.

Any thoughts?

BadTA screwed with this post 05-18-2013 at 12:44 PM
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Old 05-14-2013, 04:42 PM   #2
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Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?
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Old 05-14-2013, 05:52 PM   #3
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Originally Posted by Possu View Post
Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?



assuming the clutch parts list is the same as the 640, #28 seems to the thrust washer. or lack of. if that is the case, you have tighten the basket on to the thrust brg #32 and now that would be damaged...

or not
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Old 05-14-2013, 09:30 PM   #4
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I can confirm that there is indeed a washer (#28) and it does exist in my installation.

Any other thoughts?
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Old 05-15-2013, 01:27 AM   #5
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Originally Posted by BadTA View Post
I can confirm that there is indeed a washer (#28) and it does exist in my installation.

Any other thoughts?
Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?
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Old 05-15-2013, 08:41 AM   #6
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Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?
That's correct.
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Old 05-16-2013, 10:10 PM   #7
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I'm running out of ideas here. The inner hub turns freely until I tighten down the hex nut, then it becomes difficult to turn. I have gone over the service manual and the micro fiche. I can't find anything obvious.

Please help.
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Old 05-17-2013, 10:05 AM   #8
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Old or new parts?

If old, check if there is any markings witch way thrust washer was installed before rebuild.
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Old 05-17-2013, 10:34 AM   #9
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with or without the O ring on the inside of the plates?
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Old 05-17-2013, 10:36 AM   #10
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with or without the O ring on the inside of the plates?
No plates, only inner and outer basket.
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Old 05-17-2013, 12:28 PM   #11
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The washer is original and shows no real differences on either side.








This is what I am dealing with. The outer hub sits on the collar/needle bearing, then the washer, next the inner hub goes on and then the hex nut.

From what I can gather, tightening the hex nut pushes against the washer which pushes against the collar which pushes against the bearing in the case.

So, where is the binding happening?
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Old 05-17-2013, 12:48 PM   #12
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Check that collar/needle bearing/washer combo without any other parts, is there enought room for bearing.

Some times these washers can be installed both ways when new, but after some use only one way works.

And all parts on main shaft bearing are ok?

Can kickstarters idler gear installed wrong side out?
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Old 05-17-2013, 01:54 PM   #13
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I have checked the idler gear. I tried it both ways. I will try the install as you mention later today.

Thank you for your help!
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Old 05-17-2013, 07:00 PM   #14
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Some more pictures. The local shop thinks there is something wrong within the transmission. A washer out of place or something. If I put the collar/needle bearing on, and just the inner basket, I can tighten the hex nut and the hub spins happily. It is only when I include the outer hub.



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Old 05-18-2013, 07:38 AM   #15
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No washer after roller bearing?
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