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Old 01-02-2013, 03:20 AM   #1
mike.l OP
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Joined: Jan 2012
Location: Mid West Ireland
Oddometer: 63
Clutch Assembly

After some amount of hassle with the clutch on my '05 950 Adv, I discovered that the previous owner hadn't lined up the dots on the clutch pressure booster when re-assembling the clutch... new parts have been ordered!

Q. Do I use a clutch basket locking tool when re-assembling the clutch or as someone suggested, a special pin
that goes into the crank?
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Old 01-02-2013, 03:26 AM   #2
Hmmmm, dirt!
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Joined: Aug 2005
Location: Holland, Amserdammed
Oddometer: 1,149
pin wont do you any good as the gears side will spin with the inner clutch cage. A strong foot on the rear brake works for me, or the clutch holder.
The pin only works with a ktm special tool holding the inner and outer basket together.
999 LC8 Rat-Rally custom - 500 EXC - XR666R '85
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Old 01-02-2013, 11:52 AM   #3
mike.l OP
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Joined: Jan 2012
Location: Mid West Ireland
Oddometer: 63
Is that the same Clutch holder that's in the workshop manual's 'special tools' drawing? Part no 600.29.003.000.
I want to be able to tighten all the clutch up again once it's re-assembled. I'm a beginner here, there are no KTM dealers/workshops where I live, so I'll have a go. Anything else I need to know about?
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Old 01-02-2013, 04:30 PM   #4
a has-been that never-was
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Joined: Nov 2004
Location: Baja Sur winter. PDX summer (that's like 6 wks!)
Oddometer: 2,444
Regarding the clutch basket nut....

Check your hex socket chamfer on the inside leading edge. If its too big you will have minimal engagement with the thin nut, which can lead to slip/strip on the nut. One solution is to grind the socket back to get sufficient engagement.
"Hells AL is right."Zuber "Bad roads, good people. Good roads, bad people." Mama Espinoza
“Ride first, tart second. Sorry bro but that’s the way it has to be.” Cbrit, 2008
“You gas it where I brake!” trackday passenger, Thunderhill, 2005 "Especially since he's one of the fastest riders on the planet, on any surface!" Earwig, 2014
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Old 01-02-2013, 11:06 PM   #5
990 Adv.
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Joined: Oct 2012
Location: Bottom left hand side of OZ
Oddometer: 1,101
I had trouble getting the clutch inner nut off. Even with the air impact driver. Didnt do it for too long as I thought it would have just come right off.
What am I doing wrong?
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