Clean the oil jet for clutch lubrication.

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by KTRMN8R, Jan 14, 2007.

  1. propilot10

    propilot10 Been here awhile

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    I tried to use my strings too and it would not fit Im guessing electric guitar strings are finer. I know when you buy the strings it says the diameter of each on the package but I was not really concerned about them fitting into an oil jet for a ktm at the time. Lol. Luckily mine was clear but I need to score the right ones so I have them when I need em.
  2. T-Mac

    T-Mac orange

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    Which part number is this one? Does it fit the early 990s?
  3. beergut

    beergut Thumper

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    I upgraded to the jet that is recommended by CJ, what a royal PITA to remove. I would love to kick in the nuts whoever designed this.

    I read recommendations on removing it:
    paper clip
    superglue/nail
    clay
    bobby-pin

    what worked for me....a q-tip, after messing with it for a few hours. I put the q-tip in, smashed it in there real good and it pulled right out. Not sure if anyone has mentioned it...make sure you clean the area around the cap before you pull the cap off. Knocking grease in the hole is pretty simple to do.
  4. DirtyADV

    DirtyADV Long timer

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    Addition in red.

    /Johan
  5. T-Mac

    T-Mac orange

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    How about funnel design instead of volcano?

    [​IMG]
  6. beergut

    beergut Thumper

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    I believe that is how CJ's is designed.
  7. ABuck99

    ABuck99 0.0

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    I used tweezers like these to remove the jet once it was loosened. Inserted the tweezers inside the jet and gently removed it with out it falling off. There was enough spring tension in the tweezer to hold the jet, which also works great to put the jet back in and get it threaded lightly with out cross threading.

    I think I got a pack of tweezers from Harbor freight for under 6 bucks.
    [​IMG]

    And if you dont have access to a guitar string, you can strip some 10/12 gauge wire and use one of the strands to clean out the jet.
    [​IMG]
  8. veetwo _tls

    veetwo _tls RENOVATIO:

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    the tools that i use to remove the jet all out cleaned jet with compressed air & back together in 15min :D
    (vice grips i use with the allen key to get more leverage to crack the seal on the plug need a bit of copper pipe or something to slip over the short end of the allen key then i can do away with the vice grips)

    [​IMG]
  9. cjracer

    cjracer AWD please!!

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    The jet shown above is a standard Fuel Jet designs and was used in earlier models. It can work, but I don't recommend these or run them anymore in my bikes. Too much hassle, unless you Enjoy cleaning this jet often.

    Volcano is better as is offers some protection of the hole getting plugged instead of forcing everything down and into the center. We offer the Volcano design in stock and modified .5mm sizes as this is the current design used on All Newer KTMs. I have found the Volcano design to get plugged much less than the older version in the last few seasons of riding. I would have to inspect and clean the standard version 2-3 times a year, never knowing when it might happen. Seeing the lack of oil on the clear clutch cover was the easiest way to catch it and prevent any damage or over heating of the clutch system. With the new version I traveled all last season and never had an issues. I checked it this fall and it was still unplugged, but there was a very small amount of debris caught along the lower rim. So it looked as if it was doing it's job.

    Ready for another season!
  10. Apple Jam

    Apple Jam Forest Flyer

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    OK. '07 -990
    I purchase a new CJ Design .5mm jet, and the stock KTM toolkit flatblade screwdriver fits nice and tight/snug into the slot.

    I slip that very same screwdriver that 1"-ish down the hole and feel for the stock jet slot.
    It fits sloppy and loose, and I can't get enough downward pressure on it to break the contact.

    All my other flatblade drivers won't fit into that tight spot.
    Any suggestions?
  11. MortimerSickle

    MortimerSickle Semi-Adventurer

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    1/4" hex screwdriver bit, hold down with your finger while you turn it with an end wrench.
  12. Apple Jam

    Apple Jam Forest Flyer

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    My work van, 20 miles from home, has the right tools in it including a 3" long flat bit.
    I even have a two foot long flat driver that my brain says would be PERFECT to give pressure downward as I turn it....

    But, alas, I am limited to the little short 3/4" bits at home.....or regular screwdrivers that won't fit right.

    It feels overly tight in it's hole, and I can't get a bite on it, it feels sloppy in the slot.
    Frick. Down to 32 degrees now. Brr. Time for Whiskey !! :1drink
  13. MortimerSickle

    MortimerSickle Semi-Adventurer

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    Are you sure they are to short to reach?

    [​IMG]

    Edit: I just measured one like the one in the pic, and it is 2", so maybe 3/4 would be too short. So, maybe the whiskey is a good idea. :D
  14. Apple Jam

    Apple Jam Forest Flyer

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    I did my Google-foo before I posted, and saw that very pic.
    My biggest problem is the sloppy feel in the slot, and it's just so over-torqued that I can't get enough downward pressure.
    A good night's sleep is probly all it needs.
    See y'all in the morning!!
  15. rossguzzi

    rossguzzi 990 Adv.

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    When you have the jet out, take time to get a screw driver etc that fits nice before putting jet back in. Dont over tighten. It is only brass after all !
  16. Apple Jam

    Apple Jam Forest Flyer

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    My screwdriver fits the new CJ jet PERFECTLY tight.
    Fits like crap in the stock jet stuck in the hole...
  17. MortimerSickle

    MortimerSickle Semi-Adventurer

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    You don't have that whiskey open yet?
  18. Apple Jam

    Apple Jam Forest Flyer

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    Oh, I believe you know me better than that :deal
  19. Two Moto Kiwis

    Two Moto Kiwis Homeless Somewhere

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    I cleaned ours here in Mexico as our clutch was dragging, took the external bolt out, unscrewed the jet, got my long nose pliers with Ellens sewing needle.

    Clamped the needle with the pliers, looking down the hole I pushed the needle into the centre of the jet hole and simply pulled it back out complete with jet, does not need much pressure just enough to wedge it.

    That took probably three or four minutes max, the harder part was cleaning out what was essentially a totally blocked jet taking more than half an hour before I could poke the wire through freely, the bottom of the jet was solid.

    Mission complete, unfortunately I didn't have any whiskey :cry .... that was the most difficult bit!!!!
  20. Apple Jam

    Apple Jam Forest Flyer

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    GOT IT !!

    Two keys...
    1) cleaned the oil out of the hole so I could see it, and how buggered up it's slot was.
    2) enough downward pressure to break it loose
    The Q-Tip trick I had read about got it right out after it was loose.

    While I appreciate my dealer cleaning it at the last big service without being asked
    (only explanation I can figure, bought the bike new),
    he apparently buggered the slot, so the screwdriver fit like crap in the slot.

    I'm sure glad I had just bought the .5mm jet from CJ and had it ready to go,
    because I would never put that buggered AND clogged jet back in.

    [​IMG]