KTM DDS Clutch Inspection & Replacement

Correction- At 23:05 I discuss the belleville spring tensioner, but my description of the positions is the wrong way round. Position #1 will apply the most pressure and #3 the least pressure. Thanks to WTC for pointing this out...
Shows how to inspect KTM DDS clutch and replace the inner hub dampers and clutch plates.
2017 KTM 250EXC
KTM Clutch Kit Part # 54832011110
Tokyo Offroad Oil Drain Tool: www.tokyooffroad.com/product/o...

[@michaelsteven1090]

And yet another great video going into my "KTM maintenance" folder...Excellent.

[@johndavis1217]

Probably the best how-to videos in KZbin as far as KTM goes. Slavens Racing is good, but I think Tokyo Offroad has him beat. Excellent, your best video to date.

[@Adamthebuilder]

I did my first top end rebuild watching your videos and now I’ll be attempting my first clutch rebuild watching your videos! Thank you for the time and effort you put into these!

[@TokyoOffroad]

Pleased to hear that you are finding the videos helpful...

[@maverick2242]

some of the best instructional videos going cheers Tokyo Off Road👍

[@kurtmorelli]

Just amazing. Thank you for sharing.

[@waynemodesitt3445]

So refreshing to see a video like this that pays attention to important details. Thanks Tokyo Offroad!

[@silvakevin1]

Thank you for taking the time to do this. Very good instructor!

[@pjbuckmaster]

The best instructional videos for maintaining a KTM. Great job!

[@deloon89b]

Damn boy! you are seriously detailed! You are the kind of person that would be working on my factory edition 450sxf. Good Stuff!

[@cmedina61]

I love the attention to detail on your video. Makes rebuilding clutch packs less intimidating

[@TwoUpTourer]

Replaced my clutchpack today using the detailed procedure here. The info about checking the spring plate flatness primed me for when I discovered it was concave with the new plates, and I immediately knew what to do to rectify it. Spot on! Excellent video. (Also a member of Kansai Riders)

[@TokyoOffroad]

Thanks! Pleased to hear that you found the video useful.

[@jcbenson01]

Thank you. This video increased my confidence. And I must say, WOW what a difference the new ones made. I just bought a ‘21 sxf 450 and had heard about this maintenance item so I ordered the Rekluse set figuring it may be due. So much smoother, quieter and best of all, no more chain slap rolling through the pits!! The chain slapping around was ridiculous.

[@dennis47834]

Love your no-nonsense instructional videos! Best I've found for my KTM.

[@TokyoOffroad]

Thanks! Pleased to hear that you enjoy the videos

[@VoldHooker]

Your videos are fantastic, thanks for sharing them.

[@banshees111]

Thanks a million. All worked out perfectly. Appreciate the attention to detail. Even going make a tool from the old clutch plate...👍🙏

[@TokyoOffroad]

Pleased to hear that you found the video useful. The old clutch plate holder tool works really well so I can recommend making one...

[@AndrewBoundy]

Awesome video - when I am going to change my clutch (which is soon), this will be my guide :-) Thank you.

[@stuntfreaksteam]

thanks for the good video! i need to do this today to my 300 tpi :)

[@TokyoOffroad]

Your TPI clutch should be exactly the same as the 2017 clutch shown in the video. Hope it overhaul goes well...

[@trailswales]

Just done this :) great help thanks, on this 250tpi 2018, one of the dampers had actually broken and worn right down uneven on one side!!

[@giak-gg8vk]

i like how u work, really nice

[@ponydown4189]

Thanks for the video. I never did that style of clutch before and I just bought a 2018ktm xcw 6 days. So the clutch design is very different than my 2008 KTM 200 Xcw.

[@ozgurceylan4084]

Your videos are veery therapeutic :D thank you for great information here.

[@NirHason]

Just used the video to replace my clutch and now it's working perfect! thanks Mark! :)

[@TokyoOffroad]

Nir Hason - That’s great. I’m pleased you found the video useful...

[@NirHason]

@@TokyoOffroad I must say that the most tricky part was tightening the 6 bolts of the belleville plate.

[@cmlago]

Excelente video! Muy claro y útil. Gracias por compartirlo. Un saludo desde Argentina!!!

[@joverbuhok5222]

One of the best video for ktm... Hope you make rebuilding the engine👊👊👊

[@JaimeChannel1]

Best and most detailed videos. Thanks a lot for this from Brazil! Will help me rebuild my Husaberg TE 300 2013 clutch

[@TokyoOffroad]

Pleased you found the video useful...

[@dnrg62]

Nice vid I liked your cardboard template for the bolts ,I have 2 x 2007 450 sxf engines which we retrofitted the dds clutch into ,I really like this clutch over the earlier conventional spring clutch .cheersd

[@donski8687]

Excellent video , nicely done !!

[@sumporfuk]

Great tutorial, it guided me through the process. Thank you 👍🏾

[@TokyoOffroad]

Pleased to hear it helped...

[@almaguapa-sailboatliveaboa440]

Very well explained all along, with specs and tricks.

[@Peter-sv4nt]

Another great tutorial, thanks for putting time into these videos. I rebuilt my top end recently following your top end video, very helpful thank you. Can you make a video on how to clean a bike properly. With 160 hours on your bike and mine has sixty mine looks like it's done 560 compared. Your swing arm looks new, mine is all stained from mud, same with my hubs. The best videos on KZbin for riding and mechanical tutorials. Awesome work cheers from Australia.

[@TokyoOffroad]

Thanks for the positive feedback. Regarding cleaning, I don't really do anything special, other than clean it regularly (usually after every ride) and store the bike in the garage in a dry environment. I show how I clean my bike in this video: kzbin.info/www/bejne/g3bIk2tnfbhke8U

[@Aslexandru1]

Thank you for the videos you make Sir !

[@warwein6506]

Great video and very informative as usual, however it’s extremely difficult to take anything you say seriously after I watched your best modification video. My favorite was the power band! Please keep up the great vids.

[@TokyoOffroad]

Pleased to hear you enjoy the videos. The mods shown in the top 5 mods video are for unreal gains...

[@hphillips7425]

Excellent video. If I done this I could follow your video the first time and breeze through the job

[@bingeciren]

Excellent. Thank you for a great instructional video.

[@rdnthedirt]

I had dampers break from heat cycles in ktm that only had 40 hrs....good job Mark

[@TokyoOffroad]

Jerry Mangan - The time the dampers are sitting in the oil is also important. I think a good replacement interval is once a year, that way you should minimize any issues.

[@Papparratzi]

Learned quite a lot. Very concise and easy to follow. 🎯

[@TokyoOffroad]

Pleased to hear that you found the video useful

[@info3796]

Thank You Sir for your time, this video is perfect, very well done, congratulations. Best regards.

[@rhopping9683]

Thanks a lot for this. Really well done video.

[@bichloe]

thank you, best video replacement for sure!!!

[@miker7851]

Thanks this was very helpful to watch before attempting myself. Few minor differences on my 2020 500 EXC-F. Manual says torque is 80NM and no loctite. Everything else was pretty much the same.

[@milosbgd]

Great video Mark !

[@basilissiakwtos5113]

Really satisfying see u work 👌

[@Kolsch221]

Great videos, keep them coming.

[@otmuppet]

excellent video. thanks for posting.

[@jamessanchez8984]

Great video thank you for being so thorough

[@piuteben]

well done, 3 of my dampers were broken in two. the other 3 were spread out, lots of play. easy fix.

[@DiDoSvK]

piuteben what does the bike do when those dampers need to be replaced?

[@bikemancody2752]

Make note: clutch cover bolts, there are long sizes there. The shorter of the longer clutch cover bolts goes in by the starter. If you install the long one there it will not tighten the clutch cover. It bottoms out on the outer cases of the starter area. Learned that the hard way.

[@samp5690]

Great video. Just one question. Should the clutch throw out shaft have a rounded end on the clutch side ?

[@JaimeChannel1]

@ minute 20:36 I've got the same kit for my Husaberg 2013 Te 300. I've measured the metal disks and found: 4 disks with 1.3~1.34 mm and only 3 with 1.4mm. I wonder if that's just a fabrication variation. I've mounted the internal 1mm with the "S" mark as you mentioned, then 2x 1.3mm, then 3x 1.4mm in the middle, the other 2x 1.3mm and the top 1mm disk. Tested the bike this weekend and worked just fine. Great channel, great videos! Best regards from Brazil!

[@chrismarshall4814]

Brilliant video as usual. I have lost count of the amount of times I have referenced your videos while working on my bike. One question. What is the thickness of the fibre plates when new. To see what loss you occurred with them all reading about the same on inspection. Thanks

[@pmfilmsUK]

Fantastic demonstration

[@TokyoOffroad]

Thanks. Pleased that you enjoyed it.

[@johnhewer0]

Brilliant video.

[@attilacserkuti9237]

Thanks for the video! My new clutch set has three 1.3mm metal plates. What's the logic for putting these thinner ones to the inside? Thanks

[@danmyers4763]

What kind of effect can loose rubber dampeners have on the bike? I just ordered a new set as mine are loose themselves. The bike feels like the clutch is dragging at mid-to-top end. After inspecting the clutch, this was the only item of notice.

[@liukai6859]

Very great video, when I inspect my clutch pad, it's still more than 1.9mm, but it weared somehow forsure, should I move the bolt from position 2 to position 3? I think the clutch disk get thiner, thus the spring preload might get ligher in the same position. Am I correct?

[@paulcarden6015]

Excellent very well explained thanks

[@andybj4091]

Interesting my OEM kit for my 2017 TE250 came with One 1.0mm S, Three 1.3mm, Three 1.4mm, and one 1.0mm. I wonder if they have updated the pack since you made this video. Measured with calipers and clearly shown different then your video

[@petervanrooyen7810]

Advise Please! My KTM 2018 xc-w clutch drags with the clutch lever fully pulled in to a point that if you lock up the rear it sometimes kills the engine. Thanks for all your videos. Peter

[@TokyoOffroad]

Has it always dragged? If not, the cause is probably air in your clutch hose (replace the fluid and bleed), or the clutch master seal needs replacing.

[@Jibbs_actual]

Would the fiber thickness be the same on a 19 300i xcw? I just pulled my plates and the inner ring on the steel plates are black, fiber plates are 1.55-1.79mm thick. Can’t find the spec in my manual

[@enduro-parts-aus]

i checked my spec on the belville spring it was around 0.35mm so out of spec, i have pulled the clutch apart to replace but the clutch plate thickness is basically identical to the brand new set ! , maybe i just need to change the belville spring to get the correct tension back onto the plates ?

[@Stakuos]

Im thinking about doing this with my own 500 exc 2016 with your video as a guide. If my plates is not the same thickness as yours, should i just go from thin to thick? Lovely video btw!

[@zoranbilbiloski652]

Job well done!

[@ardhorenaissance1580]

Do U have schematic print out on ur homemade clutch tool for ktm 15 xcw 300 ? Or do U sell them. Great video by the way.tks

[@AndrewTheisintegrated]

How do i get one of those fancy Tokyo off-road oil drain tools? Looks like a compression tester fitting 😃.

[@kristjankala2784]

I didn’t pay any attention to the difference in steel plates thickness when I replaced mine, seems to be working. What happens if the steels are in wrong order (thickness wise)?

[@nickyyoung1992]

Hello love your vids could u tell me were do u get the we dampers from I'm goin 2 put a new clucth in my bike an want 2 put new dampers in 2 like u hav done here thanks.

[@gophop]

My kit had 3 metal plates, too. But not in the same quantity as yours. I put my thickest plates in the middle, as my worn pack was the worst there. More metal = more heat capacity, I figure. So they're setup as 1.0-1.3-1.3-1.4-1.4-1.4-1.3.-1.3-1.0.

[@eddycurrent413]

so the adjustment on the belvil spring tensor would stop my clutch from being so grabby ??

[@Fmontes]

Great video as always - used it to inspect and change my first clutch on my '16 300XC. Interesting that although my metal discs measured 1.0mm on the inside and outside, the four discs (going inside to outside of the bike) after the "S" disc measured 1.3mm, and the remaining four discs measured 1.4mm. My bike has less than 75 hours on it, but it has started slipping suddenly. The friction plates look good and appear to have little wear. The middle-metal plates are hued purple, and most of them show somewhat heavy wear marks. Sliding aside the rubber boot next to the clutch master cylinder, I noticed either corrosion or dried fluid. Any idea which of these could be responsible for the slippage?

[@TokyoOffroad]

If the metal plates have become very hot (you mentioned they have become hued purple) they can distort and become prone to slipping. The other thing to check is the belleville spring is flat across the face as shown in the video and tensioned correctly.

[@douchepipe5651]

Great tip for the bolts in the cardboarb👍

[@DavidGarcia-jw1df]

Is this the same for those of us with the Rekluse?

[@palmpilote]

Nice video again! Is there any different feeling after changing the hub damper? Is there any way to know the wear of them before dissemble the basket?

[@TokyoOffroad]

I couldn't really feel the amount of play while riding the bike. If it got really bad you probably would though. Anyway, I think it's a good idea to change the rubber dampers once a year or so. If you have the tools it doesn't take long and the rubber dampers are relatively cheap.

[@thegan9143]

What is the concern with the discolouration? Worried about it becoming brittle or warping? Looking at mine and likely coming up on needing to change the clutch pack. Great informative video!

[@TokyoOffroad]

David Thegan - Things to check for are heavy discoloration, hot spots and warpage. Discoloration indicates the plates got very hot. When I changed my clutch in the video it still worked fine and the fiber plates were still in spec. But due to the hours I thought it would be best to change the clutch pack anyway as I don’t want to have issues while riding.

[@matejvidmar1229]

Hello, you dont know, but you helped me a LOT. I was wondering if you know what is the difference with starting plate marked with S and the last one, both 1mm but different part number. Thanks Greetings from Slovenia

[@brunopassalacqua1828]

Hi Mark! how are you? nice video! which are the possible failures or problems if your dampers needs replacements on the hub?? you show the hub has some play...what can happen if that occurs?

[@TokyoOffroad]

The rubber dampers are there to reduce shock between the transmission and crankshaft. The rubbers will slowly degrade over time, resulting in progressively more play. So long as the dampers have not totally broken up it shouldn't cause a real issue. Of course it's best to replace the rubbers periodically, before they break down.

[@mxmike5]

Great video, Thank you!!!

[@jay_motocombat]

Great video! Which setting (1,2,or3) on the Belleville spring makes the clutch pull the lightest?

[@TokyoOffroad]

From 23:00 kzbin.info/www/bejne/eJapf36JbrioZ9E I explain the tensioner positions (Position 1= Less pressure (easiest clutch pull); Position 3= Most pressure (heavier clutch pull)). This information is correct for my 2017, but positions may be reversed on other models so best to check for your model...

[@neil4634]

Outstanding! Thank you!

[@craigwilliams3972]

My clutch steels has 3x 1.3 plates and the rest 1.4 do they still go in first

[@robinbartling7305]

First I have to say great Video!! Helped me a lot... I have a 300 EXC 2015. Clutch is not 100% the same as yours but Looks similar. I done everything like you explained it in you Video.. but if I Pop the clutch for a wheelie as exaple it Slips... checked several times... changed the Spring from y to x and z but it won't get better.. Maybe you have an advice for me..

[@TokyoOffroad]

You fitted a new clutch pack and it started slipping? Or is it an old clutch pack? Check that your clutch lever is fully disengaging (Mikhail in the comments below had an issue where his lever was sticking).

[@ptft4]

Have you ever went to the point where the clutch started to slip ? Im just changing mine and will put in new rubbers from Recluse too. It has 265 hrs on it and still feels good, maybee a slight more drag than new. Im riding tecknical enduro and slip it a lot.

[@TokyoOffroad]

Personally I've had extremely good experience with the KTM OEM clutches and never had any slipping issues. I currently use the Recluse dampers as others have said they last longer. The clutch pack, fibers and steels, I don't know of anything better than OEM.

[@jjoeabhn2526]

Cant find the spec for the plates for my ktm exc 125 i have the manual

[@guitojs]

Can I use Loctite 243 or 2701 instead of the 648, which I can't find?

[@drixsp1]

Good stuff broda 👌

[@TokyoOffroad]

Pleased to hear that you enjoyed the video

[@nitrohvy4910]

@tokyooffroad Can you point me to a good place to find clear instructional video like yours for an older 4T KTM? 2010 450 XCW SD Can't find any help anywhere. I believe those clutches all the same 2008-2012?? Pre-DDS. Do you have a video of such? Thank you for your consideration. I give you a 5star 10 out of 10 rating over others I have compared. Slavens is not as good!

[@accountsjonermining6240]

Where can i get a set of foot pegs like the ones you have on?

[@massimobroccoli9854]

Nice explained ! But still rubber for the damping ? My BSA from 1968 had also rubber dampers , and on 4000km they must be replaced ! Nothing has changed !

[@michail1963]

Mark, I am rewatching the vid as I have problems with my clutch slipping for the second time - each time after approx 60 hrs the clutch was toast. I see in your vid, when you put the pressure plate it doesnt wobble. Mine does wobble (there is 0,5-0,8 mm gap between the pressure plate and last metal plate...and I wonder why that is - i was suspecting some bubbles inside my clutch line but I think I bled them out...really strange...and all the plates are within spec...

[@TokyoOffroad]

It doesn't sound normal for the pressure plate to wobble. I'd take the pressure plate off and inspect it for damage/warpage.

[@b.patrick2570]

Would bad damper's cause a knocking noise at idle with clutch out?

[@gersonromero4967]

Best KZbin

[@hamish3766]

Unsure if the 300 is different, or its a error, but on the 4 strokes torque for the inner clutch hub nut is 80nM, not 100 as mentioned in the video. Pays to check the manual, like I didnt :(

[@1112mkt]

Very very good to learn , thank you;)

[@Tommyjreed]

Great video, I’ve just done my clutch rubbers but my clutch still sounds very chattery when clutch lever is out. Should there be rotational play on the clutch basket? Any help would be appreciated, or are they just noisy

[@TokyoOffroad]

Maybe your clutch basket is worn. In the video at 9.37 I inspect the basket for wear: kzbin.info/www/bejne/eJapf36JbrioZ9E

[@noControl556]

For the 1, 2, or 3 setting on the spring, is this adjusted by the factory for a specific bike, or can you change the setting based on preference? Such as using a lighter setting if you don't demand as much instant torque?

[@Nadnad6996]

I have the same question.

[@vxlgsi]

fantastic vid is it the same on 500 4t?

[@TokyoOffroad]

Yes, the 500 4T also uses a DDS clutch so the replacement method is the same. However, the required clutch kit part number is different, so be sure to look up your year model when ordering.

[@noahgolly4444]

When you talk about the sharp edge and the smooth edge of the steels, if you get one wrong, what would happen? I know I got my "s" plate in and faced correctly but am not 100% on my steel plate placement. After I replaced my clutch dampers and re-assembled, the clutch is working great. Is it worth inspecting again? Thanks!

[@TokyoOffroad]

If the steel plates are reversed you might experience slightly worse initial engagement after releasing the clutch (plates might stick a little). In most cases there may be no noticeable difference, but it's still good practice to orientate the steel plates with the sharp edges out.

[@timmurrayjr1324]

What if i cant get mybinner hub off i have a 2014 husky te300

[@nepicness]

Weird that on the 2012-2016 250/300s it says to use 10nm on the clutch spring bolts and the clutch cover bolts and on the newer ones it says to use 6 and 8. I just stripped one of my clutch cover bolts either because of the 10nm or it was the wrong length. Edit: So it turns out all of the bolts are supposed to stick out the same amount when fully unscrewed. One was really far in and one was far out. I switched them around and it worked fine, I tightened them to 8nm and the one I stripped had enough thread further down to hold that one. After I had stripped it the first time I would've left it except the bottom of my clutch cover was leaking oil.

[@alexandre8598]

Is it the same method for a 2019 500 EXC-F ? Thank you very much for the video.

[@TokyoOffroad]

Yes, the 500 also has a DDS clutch so the method is the same. Please check your owners manual for torques values as there may be some differences.

[@waynethepain2640]

I’ve replaced all my plates but when my bike get up to temperature gears get really stiff ? Any ideas anyone.

[@hackgolfer7352]

Another excellent video. My 2018 clutch seemed to be dragging, will adjusting the Bellville spring from II to I help? Next mod I'll be following is your idles screw video. Thanks

[@TokyoOffroad]

Clutch drag is common when the engine is cold. Does it still drag badly when warm? If so make sure that you're using the recommend oil grade and also not over-filling. If drag changed recently and became bad then it's probably air in the system (try bleeding), or the master, or slave needs rebuilding.

[@hackgolfer7352]

@@TokyoOffroad Appreciate your reply, thank you. Yes, using oil as per manual. Will double check I haven't over filled but it had a slight drag since new. My idle seems low and I haven't adjusted the bypass screw which can cause to stall on occasions when warm. Can I do harm if I adjust the Bellville from II to I? I'm yet to bleed the clutch. Thanks