KTM Clutch Replacement -How To- DIY

[@nickplank2512]

The torque spec on the bolts for the belleville washer are critical according to KTM. The single spring/belleville washer is very sensitive to pressure

[@Tikkikoira]

Hey Dirt bike tv, Your channel is honestly one of the better enduro channels on youtube. Keep up with good work sir.

[@dirtbiketv1]

Thanks, will do!

[@codenamenoob4973]

KTM have the strongest stock clutches in the business 😉

[@canonleahy3615]

i’m like 150 hours on the stock clutch

[@danortiz5101]

i forgot to put the transmission oil in my gear box the other and i ride my bike like 300 feet until i remenber i didn't put the oil,now my bike has not power at all , do you think i burn out the clutch?

[@adamdd8283]

@@danortiz5101 I accidentally ran premix oil in my tranny for 3 ride (5 hours) before noticing my mistake when going to replace the oil. I'm just now replacing the plates after 206 hours and I've only started noticing slipping in the last 4 hours. These things are bomb proof.

[@danortiz5101]

@@adamdd8283 nothing happened in my bike right now is running perfect

[@BryanVaughanDirty30]

Awesome video jay! There isn’t many out there like this I’ve sent many to this vid!

[@MangJoseTV]

Thanks for this tips. I'm a huge dirt bike lover. Really like your contents.

[@dirtbiketv1]

Glad to hear it!

[@lippser]

Dumb question, but do you drain the trans oil before you take the cover off and start doing your work? Never done it before so that’s why I’m asking.

[@TheMocard]

2018 KTM 500 is 6nm criss cross on belleville washer .. and if the spring isn't level then you have to change bolt location to a lower number hole to put more pressure on it... 10nm for the outside 8mm bolts.

[@everythingmichael5676]

How do you know if the spring is level

[@TheMocard]

@@everythingmichael5676 clutch would slip

[@rcarle]

Good video Jay. Next time you change my clutch I'll pull up this video for you.

[@boblogIIIfan]

Would be nice for some info on the order in which the discs and fibres go in, considering they are not all the same thickness

[@spencerclark2269]

Nice video, I was thinking of changing my clutch soon so I’ll definitely use this. Thanks.

[@Danman1972]

Its called a belleville washer or also refereed to as a spring washer.

[@michaelcox7101]

No torque wrench on any if that?

[@mke7876]

Is there a gasket that goes on before you put the cover on?

[@ElijahMarchand-lo3pn]

Do you have a link for the clutch kit? I have the same clutch but can’t find plates for it.

[@baotpitulas1621]

what is the number and ratio of primary and secondary gears in the primary reduction

[@5thgearpinnedmedia93]

I know this is an older video but was wondering how similar this would be for a 23/24 yz450f

[@tinymotogarage]

Great tutorial Jay. My 250 (2013) rattles like a B when the lever is out but quiet when it's in - any ideas? Forums tell me it's either "normal" or "complete disaster" (as usual).

[@dirtbiketv1]

Email Jay directly with any questions. Contact info in About tab.

[@KristofSX]

hehe perfect timing! gonna do that tomorrow :) the torque spec on bolts is only 5Nm btw :P

[@lennoncyrus8890]

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[@rogelioanakin759]

@Lennon Cyrus Instablaster :)

[@lennoncyrus8890]

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[@lennoncyrus8890]

@Rogelio Anakin it did the trick and I now got access to my account again. I am so happy! Thanks so much you saved my account :D

[@rogelioanakin759]

@Lennon Cyrus You are welcome xD

[@WillyD1]

You ever have a little surface rust on those the kit I bought had a few spots I used steel wool cleaned them up

[@randerson7761]

Thanks for the tips. 2 items I may need to check.

[@mikewelling7028]

I just broke one from the bolts of the disc spring, what do I do now?

[@user-sp8eb6iz7f]

Neither Suzuki or Yamaha say that soaking is necessary. I agree that it can't hurt, because it's a wet clutch, so the plates will end up getting oily, but it isn't going to help either. The oil level on most motorcycles is just below the bottom of the clutch basket, so the plates don't ever actually soak unless the bike is on it's side (Let's not do that!). Because or the high RPM's of the clutch basket (sometimes exceeding 14,000) any oil that gets to the clutch basket gets flung off anyway. This myth of soaking the clutch plates before installation probably came from the fact that assembling a completely dry clutch can cause the fibers to seize to the steel plates. It is for this reason that every steel plate should be covered with engine oil (both sides!) during installation. Soaking the fibers is both time consuming and unneccesary. Do you think factory certified technicians, who get paid comission, are wasting time soaking clutch plates for an hour? Just coat the steel plates and get on with it. Now here's the thing with EBC clutch fibers. Most are made of kevlar, which is different than the organic compound used on OEM plates. Kevlar based fibers should not be soaked before installation, and when the bike is started, the clutch should be slipped a few times to spin off any excess oil. It is the excess oil that causes the fibers and steels to stick together with this type of fiber plate. That's why the bike doesn't want to roll with the clutch lever pulled when the engine isn't running. This is also why kevlar based fibers are preferred by some over OEM style (less slip, more stick), and also explains the "grabbiness". Gotta give a little to get a little. You just have to decide for yourself if you want to make a little sacrifice for some gain in grab and clutch life. Finally do NOT use full synthetic oil with kevlar type clutch fibers. What's the lesson here? Coat your steel plates with oil and get on with it.

[@georgiivanov9009]

shoud i change the metal plates with new when i change the fiber plates ?

[@dirtbiketv1]

Email Jay with questions. Contact info in About tab.

[@Rickymtnatvmc]

6nm make sure to use a feeler gauge and a straight edge to inspect the clearance on the spring washer. ✌🏾

[@everythingmichael5676]

How much clearance is there supposed to be, could you explain or send me a video of some sort explaining, I just did mine for the first time on my race bike and want to make sure everything is perfect

[@davideagle4629]

Hey, I have a 2022 sx250 with 37 hours on it and I race motocross. Any idea when I should change the clutch?

[@dirtbiketv1]

Yes - email me. Contact info in About tab.

[@alveyhighway]

So Jay question.. I've taken your advice and switched over to running Rotella in my bike.. I have a 2020 crf450rwe.. I feel like the clutch feels a little jittery now.. what do you think ?

[@justinvandermerwe7428]

Late reply soz.. dont use car oil in your bike car oil has anti friction chemicals in that slips the plates so they dont grab properly use bike oil. No friction modifiers in it. Hope that helps

[@alveyhighway]

Gotta love 2 stroke any time of the day !! Ha ha love it good work

[@ziapride]

What was the brake spring replacement that you are using? The one that replaces the front spring.

[@randerson7761]

torque spec 55 INCH pounds. Very light tension on the BELLEVILLE washer.

[@reginalarenasmoran1184]

Im a B class MX rider, probably actually more like C Jeje have 64hrs on my stock KTM 2 stroke... Should I change my clutch plates or have more time ? thanks man, channel is the bomb

[@smashmunro]

Hi, would this be similar for a 2007 KTM 450 EXC?

[@dirtbiketv1]

Email Jay. Contact info in About tab.

[@OG-Hulkfish5.0]

Great information, Thanks Jay

[@robertpetty4649]

Just watched this for the first time. That spring is known as a Belleville washer. Might wanna warn folks about the washer between the throwout bearing and bottom of the hub being stuck together...and sometimes being lost. The torque spec on that Belleville washer is critical to proper operation/lifespan of the clutch...it should not be guessed at. This is not a japanese bike. Other than that, pretty easy and painless for anyone to do with minimal tools.

[@jakemyles764]

Did you need to replace the clutch cover gasket?

[@dirtbiketv1]

Email Jay with questions. Contact info in About tab.

[@56Moto]

(Torq specs for the pressure plate is 6nm )

[@STRIMIX]

Does this go for a husaberg te300 2011. Basicly the same bike as a 300 exc? My bike creeps in first gear even when warm. I want to change the plates.

[@jasonhetreed6631]

Hi, any differences in changing the clutch on a 2024 KTM 85 SX? Cheers, great channel.

[@leeirwindrums2765]

Very similar but the 85 has 3 screws on the spring instead of 5…also the manual doesn’t mention the 2 thinner metal plates but the OEM clutch pack def has them

[@michaelpope3124]

Fantastic tutorial. Thx

[@sammyyoadventures.965]

Wow thanks for tuition 👍👍

[@JohnVanHolt]

I replaced mine with the Rekluse torque drive pack. Wasn't very expensive and has a nice feel.

[@gophop]

how does it feel different?

[@gabrielattias5283]

Hello, What material do you soak the clutch pads in at the beginning of the video?

[@dirtbiketv1]

In the same oil you use in your engine

[@TheZakkmylde]

Any idea what a 2013 350 excf clutch is ? Trying to figure out if I need the clutch holding tool so I can replace the rubber dampeners and clutch plates ect.

[@ryan980]

Its exact same as the one hes doing in this video pal

[@TheZakkmylde]

@@ryan980 that was one year ago 🤣👍🏼

[@JaxsunHood50]

Hey jay, I got a 2013 KTM 250xc that won’t pull at all. Tranny fluid looked fine. No metal shavings out of the ordinary. Would this be the clutch?

[@dirtbiketv1]

Email Jay with any questions - contact info in About tab.

[@haloreach107able]

Will a 2011 ktm 300 XC-W recluse fit in a 2004 Ktm 250 exc-f?

[@dirtbiketv1]

I doubt it but call them to see

[@tripwowee3075]

Has this guy never heard about cris cross pattern 😂

[@WWRT88w]

What do the 1, 2, 3 marks do on the pressure plate? I got a new 2018 KTM 250 xcf a month back to learn trail/enduro riding and I use the clutch a bunch to hill climb. I was wondering if it would increase the "spring" pressure. Also, about how many hours before doing a clutch? Thanks for the help and videos.

[@Danman1972]

They do increase the preload on the spring. You want that washer to stay flat though. I have 130 on my 300 and just did the plates. Also, at those hours make sure the replace the rubber dampers in the hub. About a few bucks and well worth it.

[@WWRT88w]

@@Danman1972 Thanks for the tips.

[@dougeagan9123]

I'll be buying clutches for my ktm 200xc soon and was curious if you have ever tried the Tusk clutches that rocky mountain sells.

[@timetter7062]

Wow no springs? Is that cable clutch only?

[@wesleynaylor397]

Super helpful, thank you

[@1down5up_enduro]

Do you pre-soak in any oil? Would it be fine to soak in engine oil like 10-40?

[@dirtbiketv1]

Yea

[@LaurenceHoneytoast]

I put this in as you described and now my clutch won’t engage properly. The bike wants to creep in first gear even with the clutch lever completely pulled in has anyone experienced this?

[@dirtbiketv1]

First of all is the bike all the way warmed up and you had oil pre soaked the plates-- sorry but sounds like something is off-- email me if continues

[@LaurenceHoneytoast]

Appreciate your reply I made sure I soaked them for a good long while and then let the bike idle up to operating temp. It wants to creep in gear, however when I twist the throttle nothing. I did see wear or notched marks on the basket which is still stock maybe that could be it?

[@dirtbiketv1]

What bike are you on? Have you bleed the clutch ?

[@LaurenceHoneytoast]

I’m on a 14 250 xcfw. Absolutely I bled it per the manual several times no air bubbles the lever pull feels like new. I checked for a leak at the slave and master cylinder and haven’t been able to find one.

[@jayclark3425]

@@LaurenceHoneytoast If the basket has grooves that could be an issue but we usually dont see the on the current KTM's but maybe on this 2014 its possible

[@Gregg0112]

What ktm bikes use the dds clutch?

[@dirtbiketv1]

I dont have a good list but most of the current 2017 and up all do. If you really wondering about a certain model check the microfiche at clutch to see.

[@TheCarlejoseph]

Good video thanks!

[@dirtbiketv1]

Glad you liked it!

[@lozadazx14]

Thanks jay I have the same bike!!!🔥✌️

[@PackedandReadyFranco]

AWSOME VIDEO

[@philipsmith6152]

Thanks for the video, what do the number 1,11,111 on the ring mean, does 1 give less clutch bite, more etc ?

[@dirtbiketv1]

Yes 1 lighter 3 more tighter feel

[@craftgeniusideas8856]

Unique video, keep it up😍

[@D1rTyB1kEr]

Can someone tell me when is the time to replace old clutch springs to new ones and how hard is it to do? So far none in these kind of videos have not change them

[@xr280xr]

I would imagine if your clutch pads are fine and you're still feeling slippage, but I'm not a real gear head.

[@MannyRodriguez555]

You forgot to mention the difference in steel plate thickness

[@dREaDneck_Moto]

Belvile disc spring

[@SksToTheMini14]

8:29 torque spec

[@ianshort2129]

Bevel spring👆

[@lalo1276]

bro says he can break a bolt w drill but continues to use the drill 😢

[@williampage2561]

Ta da