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Old 03-12-2011, 03:16 PM   #1
rockland213 OP
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525 clutch grab?

I have a 04 KTM 525 and the clutch is very grabby
anyone have any ideas on what it could be ?

rockland213 screwed with this post 03-13-2011 at 05:45 AM
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Old 03-13-2011, 05:48 AM   #2
rockland213 OP
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anyone ?
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Old 03-13-2011, 06:02 AM   #3
wrk2surf
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sticky plates, need oil change, adjust clutch. possible master or slave leaking
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Old 03-13-2011, 08:39 AM   #4
jar944
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Grabby like you cant find neutral? or grabby like it jumps forward when you click into 1st with the clutch lever pulled in.
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Old 03-13-2011, 10:03 AM   #5
rockland213 OP
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Grabby like you cant find neutral? or grabby like it jumps forward when you click into 1st with the clutch lever pulled in.


It is hard to find neutral . there is no ease into it when the lever is let out
around mid way its go time . The bike dose not jump when put in gear
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Old 03-14-2011, 12:22 AM   #6
The Letter J
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Sounds like your clutch basket has grooves in it where the plates contact it. This causes the plates to stick and give inconsistent engagement like lurching with the lever pulled, or stuttering while releasing the lever. Pull the cover and take a look, if the grooves are very shallow, you can file them smooth and be good to go for a while. If they are deep, a new basket is in your future but you can still file the grooves down and reassemble to buy you some time. Check the stack height while you've got it apart, if you are approaching minimum you can order an individual friction plate and replace the thinnest one (this is assuming that you are cheap like me) or just get a new set of plates coming.

On the same note, if the basket has grooves/notches, more than likely the inner hub will have the same problem and I'd suggest replacing it instead of fileing due to the smaller contact area having less material to "spare."

The Letter J screwed with this post 03-14-2011 at 12:29 AM
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Old 03-14-2011, 04:10 AM   #7
DRjoe
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The 525 clutch basket is a different design than most other bikes and does not suffer from grooved baskets.
(it has a steel basket and roll pins instead of splines on the inside)

You may have glazed plates as a result from slipping the clutch, You can fix it for now by sanding the plates lightly and changing the oil.

The pressure plate on my 01 520 has holes drilled in it to allow more oil in to the clutch plates the newer 525 does not have these holes (as far as I know)
I've heard of lots of reports of grabby and squealing clutches on the newer 450's and 525's with a popular cure being holes drilled in the pressure plate.

here's my clutch others I have seen dont have the holes drilled

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Old 03-14-2011, 03:52 PM   #8
LILBIT
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Check for warped steels. I bet they're blued.
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