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Old 07-01-2013, 04:02 PM   #1
zedtours OP
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Joined: Jan 2006
Location: Surrey
Oddometer: 382
Clutch weirdness

Posted this query on UK KTM forum with no result. Fitted new clutch kit from KTM all plates and discs but now have to pull lever all the way in to disengage which makes feathering clutch almost impossible. There is no air in hydraulic system and with cover off I can see the plates being pushed all the way with the clutch lever. It has improved slightly in a couple of hundred miles. Is it just bedding in?
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Old 07-02-2013, 05:58 PM   #2
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Joined: Apr 2007
Location: Reno
Oddometer: 1,485
I always start with air in the hydraulic system. I takes so little air to reduce clutch push rod travel enough to impact disengagement. Beyond that possibly a mismatch between the new clutch pack and the push rod. I have heard of (but not experienced) a need for a different rod or shimming to get full disengagement.

Good luck
KTMs--300, 518, 990
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Old 07-02-2013, 06:28 PM   #3
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Joined: Nov 2006
Location: Jefferson, GA
Oddometer: 2,095
Make sure the clutch master cylinder is topped off. Very small capacity . . . If the level is down it will not engage fully etc.
"In the end, it's not going to matter how many breaths you took, but how many moments took your breath away"
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