Clutch Assembly

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by mike.l, Jan 2, 2013.

  1. mike.l

    mike.l Adventurer

    Joined:
    Jan 26, 2012
    Oddometer:
    63
    Location:
    Mid West Ireland
    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?
    #1
  2. StevenD

    StevenD Hmmmm, dirt!

    Joined:
    Aug 3, 2005
    Oddometer:
    1,151
    Location:
    Holland, Amserdammed
    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.
    #2
  3. mike.l

    mike.l Adventurer

    Joined:
    Jan 26, 2012
    Oddometer:
    63
    Location:
    Mid West Ireland
    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?
    #3
  4. HellsAlien

    HellsAlien a has-been that never-was

    Joined:
    Nov 16, 2004
    Oddometer:
    2,447
    Location:
    Baja Sur winter. PDX summer (that's like 6 wks!)
    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.
    #4
  5. rossguzzi

    rossguzzi 990 Adv.

    Joined:
    Oct 21, 2012
    Oddometer:
    1,136
    Location:
    Bottom left hand side of OZ
    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?
    #5