Clutch hard to turn

Discussion in 'Thumpers' started by BadTA, May 14, 2013.

  1. BadTA

    BadTA Adventurer

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    I am rebuilding my KTM 625 LC4 and am at the point where I am re-installing the clutch. I have put the clutch basket in and then the inner hub. At this point the inner hub turns freely. Now, when I tighten down the hex nut to the specified torque (60 ft.lbs.) the inner hub is now hard to turn.

    Any thoughts?
    #1
  2. Possu

    Possu de-nOObed!

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    Perhaps you're missing some sort of thrust washer behind the clutch hub/basket?
    #2
  3. shipwrek12001

    shipwrek12001 Shipwrek

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    :nod

    assuming the clutch parts list is the same as the 640, #28 seems to the thrust washer. or lack of. if that is the case, you have tighten the basket on to the thrust brg #32 and now that would be damaged...

    or not
    #3
  4. BadTA

    BadTA Adventurer

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    I can confirm that there is indeed a washer (#28) and it does exist in my installation.

    Any other thoughts?
    #4
  5. Captain115

    Captain115 Been here awhile

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    Just to double check: you don't have any of the plates in right, its just the inner and outer baskets?
    #5
  6. BadTA

    BadTA Adventurer

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    That's correct.
    #6
  7. BadTA

    BadTA Adventurer

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    I'm running out of ideas here. The inner hub turns freely until I tighten down the hex nut, then it becomes difficult to turn. I have gone over the service manual and the micro fiche. I can't find anything obvious.

    Please help.
    #7
  8. Seikkailu_R

    Seikkailu_R Been here awhile

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    Old or new parts?

    If old, check if there is any markings witch way thrust washer was installed before rebuild.
    #8
  9. wrk2surf

    wrk2surf on the gas or brakes

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    with or without the O ring on the inside of the plates?
    #9
  10. Seikkailu_R

    Seikkailu_R Been here awhile

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    No plates, only inner and outer basket.
    #10
  11. BadTA

    BadTA Adventurer

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    The washer is original and shows no real differences on either side.


    [​IMG]

    [​IMG]

    [​IMG]

    This is what I am dealing with. The outer hub sits on the collar/needle bearing, then the washer, next the inner hub goes on and then the hex nut.

    From what I can gather, tightening the hex nut pushes against the washer which pushes against the collar which pushes against the bearing in the case.

    So, where is the binding happening?
    #11
  12. Seikkailu_R

    Seikkailu_R Been here awhile

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    Check that collar/needle bearing/washer combo without any other parts, is there enought room for bearing.

    Some times these washers can be installed both ways when new, but after some use only one way works.

    And all parts on main shaft bearing are ok?

    Can kickstarters idler gear installed wrong side out?
    #12
  13. BadTA

    BadTA Adventurer

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    I have checked the idler gear. I tried it both ways. I will try the install as you mention later today.

    Thank you for your help!
    #13
  14. BadTA

    BadTA Adventurer

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    Some more pictures. The local shop thinks there is something wrong within the transmission. A washer out of place or something. If I put the collar/needle bearing on, and just the inner basket, I can tighten the hex nut and the hub spins happily. It is only when I include the outer hub.

    [​IMG]

    [​IMG]
    #14
  15. Seikkailu_R

    Seikkailu_R Been here awhile

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    No washer after roller bearing?
    #15
  16. BadTA

    BadTA Adventurer

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    I don't see one either in the manual or in my bucket of parts.
    #16
  17. Seikkailu_R

    Seikkailu_R Been here awhile

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    Its part of that roller bearing, not a part with its own number.

    Here is some pictures...
    #17
  18. BadTA

    BadTA Adventurer

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    If you will send me your address I will gladly send you a case of your favorite beer!

    [​IMG]
    #18
  19. Seikkailu_R

    Seikkailu_R Been here awhile

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    No need for that, advices on internet are free...
    #19