Clean the oil jet for clutch lubrication.

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

  1. tkorpi

    tkorpi Been here awhile

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    I finally worked up enough nerve to give it a nice, strong twist with the screwdriver. It came out, but I was pretty surprised by how tight it was . Anyway, instead of a shop vac, I used a bobby pin to extract it. I cut off the curved tips of a large bobby pin and bent the 'legs' outward. I basically made reverse action tweezers. Worked like a charm!
    #41
  2. cpmodem

    cpmodem Orange Caveman

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    This is what I use to remove/replace (after broken loose) this type of jet:
    -cp

    [​IMG]
    #42
  3. gefr

    gefr Life is a trip

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    I used cpmodem's method with the screwstarter, but the problem is it dents the middle of the screwslot! Can we have a photo of the bobby pin method please? Thnx!
    #43
  4. tkorpi

    tkorpi Been here awhile

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    I used another bolt for simulation purposes.


    [​IMG]
    [​IMG]
    #44
  5. cpmodem

    cpmodem Orange Caveman

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    Brilliant!
    #45
  6. Ricardo

    Ricardo Adventurer

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    I have been following this thread and decided to check my reduction jet.
    removed the slave cylinder , chain guard/guide ect removed the M8 blanking bolt , i then unscrewed the brass screw which sits at the bottom of the hole, finally using the vacum cleaner with some reducing pipe i got the little bugger out, Guess wot NO OIL HOLE .
    All 03 models had a brass plug pt no 600.038.027.000 this should have been replaced with Reduction jet pt no 600.38 029.000 as part of scheduled service it is suposed to improve clutch function .
    My machine had all of its servicing work done at Red Line up untill the waranty ran out . Mileage to date is 20000 miles also on origional slave cylinder.
    I will be over to Red Line first thing Monday morning .
    #46
  7. tkorpi

    tkorpi Been here awhile

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    Thanks cpmodem! Kills me that in the Repair Manual they show a pair of tweezers being used to pull it out. I tried that for about 10 infuriating minutes before I stomped off in search of another solution...

    The 950 SM and this board are slowly turning me into a crappy mechanic. I've got a CBR 600 in the garage with 62k miles on it and I was happy to only ever change oil/chains/sprockets. My 950 has 4.4k miles on it and I've had the bloody thing in pieces! In fact, it's in the garage right now with the carbs hanging off the bars so that I can finish a little unfinished ectomy business! Friggin' KTMs! :rofl
    #47
  8. unaweep

    unaweep Uses lotsa band-aids

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    So, I managed to remove the little brass "screw" which has a "hole" in the top of the screw, in the center where the slot is for a flat tip screw driver. But it is such a small hole that a pin won't fit in there. It looks to be the diameter of a human hair. I certainly cannot see any light through it. WTF? Is this right? Is this the problem mentioned by Ricardo? Is this why my clutch plates look likme they got real hot, as the dealer mechanic told me? This is an 05.5 950 Adv.
    #48
  9. tkorpi

    tkorpi Been here awhile

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    Sounds like it must be clogged. You should be able to see some light through there. Should be roughly .02" or 1/50" in diameter.
    #49
  10. kamanya

    kamanya Andrew to most

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    Um... Ok, so in the name of being inquisitive I once took the clutch cover off and then seeing that it was practically dry in there I started the engine.

    It was only after a few blips did I notice that a bit, and I mean only a bit of oil was being sprayed onto the swing arm and the foot peg and floor.

    So, I can deduce that not a lot of oil gets to the clutch. I have a 2004, spec'ed to 2005 and I have yet to check to see if I have one of those jets with the holes.

    Just my 2 cents, not sure its worth much though.
    #50
  11. TMoore

    TMoore Arai Test Dummy

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    I just pulled mine, (an 04) and its plugged as well. I had developed
    a real bad clutch chatter last year but it went away with the installation
    of the newest clutch rod. It hasnt given me any problems since but... Ill be
    ordering the new jet.
    #51
  12. KTRMN8R

    KTRMN8R Sand Camel

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    Hey Fellas,
    Wow! Didn't expect so much feed back on this thread, glad everyone's clutch discs will live a little longer(mine too). I got lucky when I serviced mine a week or 2 ago because it was clean.:clap
    In regards to drilling jets,... I've always thought this a bad idea :huh (for oil jets or carburetor jets). :ear Once a "jet", or 'venturi' if you like, is drilled it becomes more of a low pressure weep hole:cry . The oil will come out thicker and have less of the "spray effect" (in the case of carb jets,... the fuel air mixture will not atomize correctly).
    I do understand the thought of a larger hole being less maintenance and more effective than a clogged hole, but I've accepted the fact that I'll have to perform this check more regularly to maintain optimum performance:D .
    Just my 2 cents fellers:freaky Happy Trails!
    #52
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  13. gefr

    gefr Life is a trip

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    The hair thick jet hole is 0.30mm diameter and is really thin. The oil pressure though is high enough to deliver enough oil to the clutch! You could test it connecting it to an elastic hose and pressuring some water from the tab. It is difficult for the light to pass even if some oil is in the hole.
    #53
  14. unaweep

    unaweep Uses lotsa band-aids

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    Thanks Gefr. I was able to slide a hair through it, so I guess it's ok. Geez thats a small hole. It was clogged.




    QUOTE=gefr]The hair thick jet hole is 0.30mm diameter and is really thin. The oil pressure though is high enough to deliver enough oil to the clutch! You could test it connecting it to an elastic hose and pressuring some water from the tab. It is difficult for the light to pass even if some oil is in the hole.[/QUOTE]
    #54
  15. UKstu

    UKstu Adventurer

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    Hi
    I have a 03 from new. It has stated developing a cluch slip on pulling away. There is no slip once the clutch is engaged. I got suspicious of the jet so pulled it appart. I used a syringe to remove oil sitting on top of the plug where did this oil come from??? Hey presto NO oil hole just a plug.

    How does the jet improve clutch function ?? I have 22,000 miles on the original clutch.

    I assume the jet only jubs the push rod not the plates.

    Last where do i stand now it's out of warranty. I don't want to take it to the same jokers who failed in the first place.
    #55
  16. K2m

    K2m ....58....

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    I to would like to know how all this works. There must be a separate jet to lubricate the clutch, and when I opened mine up I could not select neutral:norton
    #56
  17. Ricardo

    Ricardo Adventurer

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    I took my brass plug to my local dealer, Red line, and they have ordered the jet and are posting it on to me free of charge. it would seem that the new jet should have been fitted when the bike was brand new sept 03 as KTM were aware of a problem with push rods.
    If you look down the hole using a torch and mirror you will see a small slot in one side of the bore just bellow the 8mm threaded section, oil is forced through here and then down thro the jet and so lubricating the push rod .
    #57
  18. HellsAlien

    HellsAlien a has-been that never-was

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    I used a cuticle scissor to pull the jet out of the hole. Stick the tip of the scissors into the ID at top of the jet and spread to grab it and pull it out.
    Easy, worked good.
    #58
  19. gefr

    gefr Life is a trip

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    when you opened your...clutch? you could not select N. Did you remove the discs? Did you leave the engine to warm up?
    #59
  20. claferal

    claferal Been here awhile

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    My mechanic took a chewgum at the end of the screwdriver and catched the oil jet with it. Easy and effective
    #60