Clutch hard to turn

BadTA · 05-14-2013, 12:49 PM

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?

Possu · 05-14-2013, 03:42 PM

Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?

shipwrek12001 · 05-14-2013, 04:52 PM

Quote:

Originally Posted by Possu

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

BadTA · 05-14-2013, 08:30 PM

I can confirm that there is indeed a washer (#28) and it does exist in my installation.

Any other thoughts?

Captain115 · 05-15-2013, 12:27 AM

Quote:

Originally Posted by BadTA

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?

BadTA · 05-15-2013, 07:41 AM

Quote:

Originally Posted by Captain115

Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?

That's correct.

BadTA · 05-16-2013, 09:10 PM

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.

Seikkailu_R · 05-17-2013, 09:05 AM

Old or new parts?

If old, check if there is any markings witch way thrust washer was installed before rebuild.

wrk2surf · 05-17-2013, 09:34 AM

with or without the O ring on the inside of the plates?

Seikkailu_R · 05-17-2013, 09:36 AM

Quote:

Originally Posted by wrk2surf

with or without the O ring on the inside of the plates?

No plates, only inner and outer basket.

BadTA · 05-17-2013, 11:28 AM

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?

Seikkailu_R · 05-17-2013, 11:48 AM

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?

BadTA · 05-17-2013, 12:54 PM

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!

BadTA · 05-17-2013, 06:00 PM

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.

Seikkailu_R · 05-18-2013, 06:38 AM

No washer after roller bearing?

05-14-2013, 12:49 PM	#1
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	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 11:44 AM

05-17-2013, 09:05 AM	#8
Seikkailu_R Studly Adventurer Joined: Jun 2007 Location: Piikkiö, Finland Oddometer: 814	Old or new parts? If old, check if there is any markings witch way thrust washer was installed before rebuild. __________________ -- "The concept of a versatile motorcycle equally at home on dirt and pavement is as old as motorcycling itself"

05-17-2013, 09:34 AM	#9
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,310	with or without the O ring on the inside of the plates? __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

05-17-2013, 11:48 AM	#12
Seikkailu_R Studly Adventurer Joined: Jun 2007 Location: Piikkiö, Finland Oddometer: 814	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? __________________ -- "The concept of a versatile motorcycle equally at home on dirt and pavement is as old as motorcycling itself"

05-18-2013, 06:38 AM	#15
Seikkailu_R Studly Adventurer Joined: Jun 2007 Location: Piikkiö, Finland Oddometer: 814	No washer after roller bearing? __________________ -- "The concept of a versatile motorcycle equally at home on dirt and pavement is as old as motorcycling itself"

05-14-2013, 03:42 PM	#2
Possu de-nOObed! Joined: Jan 2004 Location: Oxford, UK Oddometer: 5,052	Perhaps you're missing some sort of thrust washer behind the clutch hub/basket? __________________ www.possu.smugmug.com

05-14-2013, 08:30 PM	#4
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	I can confirm that there is indeed a washer (#28) and it does exist in my installation. Any other thoughts?

05-16-2013, 09:10 PM	#7
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	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.

05-17-2013, 11:28 AM	#11
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	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?

05-17-2013, 12:54 PM	#13
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	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!

05-17-2013, 06:00 PM	#14
BadTA ^OP Adventurer Joined: Sep 2010 Oddometer: 62	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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