No hole in clutch oil jet

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by sti_rx7, Jan 6, 2013.

  1. sti_rx7

    sti_rx7 Been here awhile

    Joined:
    Nov 26, 2005
    Oddometer:
    125
    My clutch has been feeling kind of sticky lately and I figured I would clean the clutch oil jet. I got it out and saw some muck in there tried to push it through and did not budge. All the oil and muck was cleaned out with carb cleaner. I looked into the hole and all I saw was clean brass that blocked the orifice. I tried pushing through with a tiny allen head head wrench and it just hits the solid brass "wall". No compresssed air goes through it as well. ???????

    on a 2004 GO!!!!!:huh
    #1
  2. stuj

    stuj Adventurer

    Joined:
    Aug 17, 2011
    Oddometer:
    33
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    Gods own County, North East UK
    On the early bikes like yours there was no hole in this, it is a blanking plug.
    You can fit an oil jet as a mod.
    Hope this helps. :wink:
    #2
  3. sti_rx7

    sti_rx7 Been here awhile

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    So what's the use of the oil jet then?
    #3
  4. stuj

    stuj Adventurer

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    It lubes the clutch actuator rod. The early bikes did not get enough oil through the case to stop them sticking AFAIK
    #4
  5. cjracer

    cjracer AWD please!!

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    Lubes the internal parts of the clutch, booster system.

    .3 is standard KTM. We offer a modified .5mm for more oil flow and cooler clutch running.

    More info here.

    Might want to upgrade to the one piece pushrod too at that time.
    #5
  6. sti_rx7

    sti_rx7 Been here awhile

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    Thanks! You're a great salesman may have to buy one :rofl
    #6
  7. gefr

    gefr Life is a trip

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    Since yours is made of brass, I would think it has the tiny hole. However it seems yours is blocked. #30 is the original, not the same with 0.30mm. I would advise 0.50mm gives better results.
    #7
  8. DuctTape

    DuctTape Been here awhile

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    My 2011 was sealed as seen under my super duper Mr. Magoo Magnifying glass so I clamped her to the drill press and kept nudging the glob until the hole showed up. Cost me clutch in clay mud to discover it.
    #8
  9. rossguzzi

    rossguzzi 990 Adv.

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    I had a .3 and wanted to get a .5
    I took it to a watch maker and he drilled it for free !
    #9
  10. TcRulz

    TcRulz Been here awhile

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    My 03 950A had a solid brass plug:eek1. Bought ten 0.5 drill bits for $2 off eBay and wasted five of these trying to drill a hole in that sucker. So bought an 0.3 oil jet and had no trouble hand drilling to 0.5mm:D.
    #10
  11. Rockwell

    Rockwell Been here awhile

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    Can someone elaborate on this? What it's the pushrod's function? Is it what presses on/releases the clutch plates? And why go to a one-piece?
    #11
  12. cjracer

    cjracer AWD please!!

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    the 3 peice units have shown to collapse over time.

    Are you not getting full release of your clutch system? This might be part of the problem.

    A search might find old posts where this was found to be the issue.

    Deadly99 was one if I recall.
    #12
  13. zedtours

    zedtours Been here awhile

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    If you have a spare case/engine, piston jet 0.6 works fine and same size OD
    #13
  14. Zuber

    Zuber Zoob

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    The three piece push rod did not have enough clearance, would rub and generate metal filings, and it would fall apart. The oil was supposed to travel down the center of the rod to oil the clutch.

    The one piece is steel and a much smaller diameter. The oil flows on the outside. It doesn't fall apart or rub.

    I've never heard of a plastic plug, the early ones had brass with no hole, then about early 2005 KTM put in an orifice. These need to be cleaned every 20k or so.
    #14
  15. bigkuri

    bigkuri Long timer

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    I suspect they have a grab-bin of jets... I have a 2011 Adv R and utterly no hole from new, an obvious cock up by the factory... Bored it out, but then eventually replaced it with a 0.50 from CJ - a very good mod with shifting
    #15
  16. DuctTape

    DuctTape Been here awhile

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    Same with me and why everyone should check their jet even 2012 and 2013 owners
    #16