KTM 790 Clutch Jet

[@rodgerdodger1625]

Good video. The service manual even has an optional check of the jet to ensure that it is not blocked by debris. I would suggest to everyone to insist the dealer does this at every service and get it documented, because if the jet blocks and your clutch fails you are looking at thousands to have your engine fully rebuilt.

[@CodgerBiker]

It certainly focuses the mind. Cheers! 👍👍

[@98cold60]

Thanks CB. I didn't realize how small that is. Keep up the good work on the channel. You are my favorite. You actually inspired me to start my own channel...I'll mention you a few times.

[@CodgerBiker]

Brilliant. Possibly the best comment I’ve ever received. I shall subscribe forthwith - good luck 👍😁

[@greatfallskam]

I purchased a new KTM 890 ADV. Any more information, videos , or updates on the oil injector for clutch? Seems like your 8 Awg. guitar string should be adequate for making sure the holes aren't plugged; without having to remove the injector.

[@CodgerBiker]

Not heard anything about the 890, I've been wondering myself. Main thing is to make sure they check it at service I guess 👍

[@RedRupert64]

The 950/990's clutch jet should also be checked at each service. I squirt brake cleaner through it, once removed. In the old days people used to discuss replacing them a larger one. I don't know why - my bike has done 125k miles and it been fine with the original item.

[@CodgerBiker]

Yes there’s the same movement happening with the 790. I wonder if the failures happen early due to badly applied loctite blocking it. If you aren’t unlucky, and (as you say) you clean it at service then your experience is evidence KTM know how to design a clutch. Of course good news never goes viral 👍

[@steevkeyes]

Yesterday I took my new 790 Duke in for first 1000 km maintenance. Mechanic suggested he include disassembling the clutch to air-blast the oil jet. I agreed. Later, after driving away, I found the clutch was slipping whenever I gunned the engine (under load). Immediately took the bike back; mechanic reassembled the clutch - he confessed he previously put some of the clutch plates in wrong!!!

[@CodgerBiker]

Good information. Not that they put the plates back incorrectly, that is bad luck. But the confirmation that they air blast the oil jet to clean it, as suspected. 👍

[@Advcrazy]

I bet an acupuncture needle would be a good alternative to a guitar string. Pretty springy and even have a little handle in them. I use 0.3mm needles for dry needling).

[@SomeRandoInternetPoster]

Coober put a post out last week comparing clutch temperature with stock and enlarged jet. On the road they noticed no difference but off-road the enlarged jet kept the clutch significantly cooler. I guess that’s because you are using the clutch more off-road and larger jet has more airflow. Like yourself I’ll look at it when out of warranty.

[@CodgerBiker]

Now that is good information and matches my own view, if a clutch is being slipped hard it needs lubrication more. On road you rarely do this. Still, it should be built to do both. 👍

[@ossie7940]

Interesting..the blocked jet was the problem on my bike when I had just run it in. Took several weeks to solve the problem.as my bike would not engage 4th gear smoothly Eventually sorted out by the dealer.and emails to KTM Something that will need cleaning on a regular basis I believe Have you had the brake pipe recall completed yet ? Have had mine done.takes 2 hours as tank off etc.

[@CodgerBiker]

Hi Ossie. Yes it all seems a bit narrow to me, 0.3mm. But understanding is half the battle I guess. Mine is in next month for that job. Delayed as my dealer is in another country. I don’t think my mainly road going bike needs it, I’ve checked many times, it’s never that warm. 👍

[@MelvinMelv10]

How many torque for the three bolts ?... Tanks

[@CodgerBiker]

10nm from memory. But I would advise you to check your owners handbook 👍

[@MelvinMelv10]

@@CodgerBiker yes it is 10nm.. Youre right.. Thanks

[@progammler]

Thanks for the video! I was thinking about buying the Camel clutch lever but was afraid that it would make me use the clutch even more (I am used to 300cc so I already play a lot with it). Does someone have experience with a Recluse clutch on this bike? Maybe it can handle the heat better. I have had so many issues with my 790 already... thinking about letting KTM do the inspection once a year so that the warranty gets extended up to 80.000km. Repair costs would easily be more than those 400€. I have a feeling that this bike is not going to age well as I already had to bring it back to the dealer 5 times within the first year. 2x display replacement (and still water inside), fuel gage getting stuck, brake line recall, rear shock absorber seal broke at 13.000km and the list goes on... I am also still getting the key error when shutting the engine off with the button so I need to turn the ignition off and back on again before I can start the engine and they can't figure out what it is.

[@CodgerBiker]

Blimey, that’s an alarming number of events. I generally use the quickshifter once moving, but offroad feathering is natural for any experienced rider I think; essential in fact even with rally mode. It’s really hard to judge as an owner isn’t it? When something fails it makes headlines. When someone says I’ve done 20,000 km without incident nobody listens. I like to try to understand my vehicles. With this one there certainly seems to be a lot to be aware of. If keeping it I’d consider the warranty extension myself. It’s such a great riding bike, real fun. But it’s hard not to be concerned. For what it is worth I’ve ‘heard’ of some who replaced it with a Rekluse and had it ‘fail’. But there’s no way to know the circumstances. I’m 90+% road riding, so I’m sticking with the stock for now. 👍

[@martijnmw]

Interesting video. Further do you intend to install Factory Pro - KTM 790 Pro Shift Kit (Ceramic Bearings)? Myself have sometimes false shift from 1 to 2 but than going to neutral.

[@CodgerBiker]

Thank you. I have no plans in that direction. I am looking forward to some riding weather soon 👍

[@progammler]

I have the quick shifter and never get into neutral by accident. I am actually quite amazed by how easy it is to put it into neutral at stand-still and how easily it goes into 2nd once you are rolling (with or without clutch). In comparison I have to slam the shifter with all my force on my 300cc... Does this only happen when shifting up or down or both ways? If it's just one way then maybe try repositioning the lever maybe you are just not pushing it far enough?

[@mwjd58]

Wasn’t the film Seven, or am I making the wrong connection? Gwyneth’s head in the box, without showing it. BTW, thanks for helping demystifying the 790 clutch issue.

[@CodgerBiker]

Ha ha! Yes you are correct and my senility grows ever more worrying. Ten was a Bo Derek film, probably why I remembered it. Still you understood, the ability of human minds never fails to astound me - wish I had one! 🤪😁

[@ulyssescale]

He called it 10 because of the metric system.

[@Johnr37us]

I just smoked a brand new 800 dollar ( U S ) Recluse auto Clutch yesterday because of this problem. The bike and had the 600 mile service already done and the bike at the time of destruction had 1300 miles on it.

[@CodgerBiker]

Some people have fitted a slightly larger jet, or slightly reamed the stock I believe. Though how that affects overall engine oil pressure is hard to know. Lots of older KTM owners, apparently, did this. Better, perhaps, is make sure it is cleaned at every service. Was it threadlock do you know? I’ve heard of cases... sorry to hear you had that ☹️

[@PAKAYODA]

Where did you get those thin needles? How thick is it?

[@CodgerBiker]

Needles? I do not understand. The jet is a powerpart, you can see the number on the box. The drill is 0.5mm from Amazon.

[@PAKAYODA]

@@CodgerBiker Did you drill a new hole with 0.5mm drill feet??

[@CodgerBiker]

No, in the end I did not. But I know of several people who have done so 👍

[@Clampett01]

You lost me on this one Codger. Why did you buy it?, why are others buying it? should I buy one? What clutch problems? Do I need to clean my hole with a G string?

[@CodgerBiker]

Ha ha, brilliant! A G string would not fit! Just more KTM foibles, buy with your eyes open, as well as the clutch jet!

[@Johnr37us]

Here’s the update on my oil jet issue The only way I could get it out was with an impact and it had a large amount of Loctite on the threads. As far as making the whole larger I don’t see where that will help anything so I just ordered a new one and if it’s modified by KTM then that will be the only modification It gets.Because I don’t think it ran out of oil because the hole was too small but it ran out of oil because it got stopped up by trash that was residual Loctite . And it had 1400 miles on it when it went down because it has a Recluse auto clutch in it KTM’s sees it as my problem.

[@CodgerBiker]

I've heard as much and agree I'd be reticent to increase the jet size. Loctite blockage appears common. Not really needed in my opinion, but I'm not KTM. More important is it is checked at service. I hope you get your bike sorted. It is a great machine. 👍

[@espero7757]

Music is the solution 😁

[@CodgerBiker]

Most certainly true - unless I am playing it! 👍

[@stevecade857]

Thanks for the info. If I suffer from difficulty finding neutral or engaging other gears I'll be at my dealers door mentioning the clutch jet.

[@CodgerBiker]

Hi Steve. Sounds like it needs investigating. I’m just trying to get a handle on what is going on, best I can. Obviously all clutches can fail, but there appears to be a pattern for some. I hope they sort it. Let us know what they find 👍

[@stevecade857]

@@CodgerBiker I don't have any issues. My 790 is probably the smoothest, easiest shifting bike I've owned and believe me I've owned a few. Just your info is great if I do experience any trouble. KTM are not renowned for ultimate reliability but that's what a factory warranty is for.

[@CodgerBiker]

Ah sorry Steve I missed the 'If'. Just been out for an hour's blast on mine, fast roads, B roads, tracks and city - perfect bike for me. Of course reliability talk is enough to make one paranoid, who said that?! 👍😁🤣😂

[@NMdesertracer]

Been using the .5mm jet for 2 months clutch looks way better!

[@CodgerBiker]

A few people have told me they have no problems. Being cautious (and not wanting to strip the head of the loctited jet) I'd be inclined to wait while the warranty ran out - not that it covers the clutch. 👍

[@NMdesertracer]

@@CodgerBiker On mine there was a lot of loctite. I had a old pencil style soldering iron in my house so I heated the jet up with that lol. I ordered a pre drilled jet tho knowing my luck I would do a proper bust off the drill bit inside the jet.

[@CodgerBiker]

That's kind of the approach I would have gone with. Have the new jet ready and use heat. Top job. I'm still not doing it while in warranty though. But thanks for sharing, appreciated. 👍