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Cluster of clutch failures on KTM 790 Adventure
- Thread starter Tim Cullis
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Never had an issue on my 950s
Yes but to be fair yours were used mainly as a road bike with consequently less clutch use/abuse.
The issue really arose with early 950s and was generally sorted after 2003 but many owners of later bikes still fit an oversize jet.
Good point well made
Did the same with my 990. Sounds like it would be worth exploring on the 790.
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Checking/clearing the clutch jet is an item on the 18K service (and possibly the 9K), but I doubt many bother with it as it's a bit awkward.
Some bikes had clogged fuel filters from in-tank crud - mine not. I wonder if there's been some in-engine crud on some bikes that's blocked the jet? That would explain the first post wouldn't it? Replaced clutch and then it failed again. It does sound like a blocked jet or some such thing. No-brainer to check it.
Someone will post something definitive on this I expect. But it's really bad for KTM not to fix this issue on affected bikes and I have to say that a BMW dealer would be sorting something like this under warranty with few questions asked about riding 'style'...how ridiculous. Either the 790 is designated for off-road abuse or it's not!
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Of course the 790 issue may turn out not to be the oil jet, but surely it's worth experimenting.
The increase in diameter for the jet on LC8s is only around 0.5mm.
Jo highlighted checking for a blockage due to Loctite which perhaps is used on assembly but if like the LC8 the jet is brass then then I wouldn't personally use Loctite
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The size of jet fitted as standard is supposed to be marked '30' for 0.3mm but at least one owner has found his bike had a '25' jet.
Rekluse, the clutch company, are reported to have also said this has happened. But other owners with failed clutches have had '30' jets.
I’ve read that increasing the jet size can have an impact on the ease of finding neutral??
Rekluse, the clutch company, are reported to have also said this has happened. But other owners with failed clutches have had '30' jets.
I’ve read that increasing the jet size can have an impact on the ease of finding neutral??
Of course the 790 issue may turn out not to be the oil jet, but surely it's worth experimenting.
The increase in diameter for the jet on LC8s is only around 0.5mm.
Jo highlighted checking for a blockage due to Loctite which perhaps is used on assembly but if like the LC8 the jet is brass then then I wouldn't personally use Loctite
Tim,
I wouldn’t dare to suggest any servicing advice - I’m a completely bumpity numpty with practical stuff. The reference I made to thread lock and checking for blockage in the jet is in the 790 service manual.
Joe
Correct, it's one of the side effects as the additional oil flow can increase clutch drag.
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Different application I know but I've drilled addition holes in the pressure plate on my rfs engine to alleviate this.
Whaaaat! Check out this guys clutch frictions/plates! Looks like zero oil to me and he pops an expensive Rekluse straight in....
I can't help thinking the oil must've been pretty black to. Mines on the ramp now...will take a photo or 2 and post findings.
https://www.youtube.com/watch?v=AQNXnVmDRNY
LC8. But food for thought although note many other clutch modifications were made in addition to larger oil jets.
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Cluster: a group of similar things that are close together
Owners started taking delivery in March, no initial problems, then a "cluster" of clutch failures were reported more or less at the same time. Some involve nothing more than replacing the clutch and carrying on, in other cases the clutch disintegrated and the engines need to be stripped down and rebuilt.
Other than Bill Cairns, I don't know how many of the failures are for UK owners, but with less than 200 R and S bikes delivered to the UK, 1 failure (0.5%) is still a sizeable proportion.
Here's another rebuild candidate just come in, see https://www.facebook.com/groups/1824483411197787/permalink/2311226815856775/
The guy has a 2017 BMW 1200 GSA (which of course also has a wet clutch) which is running fine with 24,000 km on the clock, and the beamer has done a lot more off-road that the 790 which failed after only 2,200km.
The KTM dealer has told him that delivery date for new clutch pack is 18 Feb 2020.
Here you go....what do you reckon? It's been used 40/60on/off road to date. Not just fire roads, a good mix of knarly and easy.
At least it looks better than the one above!
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At least it looks better than the one above!
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INTERESTED TO KNOW WHERE THE OIL JET IS LOCATED. ANYONE GOT ACCESS TO A WORKSHOP MANUAL? I'VE TRIED DOWNLOADING FROM THE KTM 790 LOOK AT ALL THE ISSUES.COM BUT IT FAILS.
No need to shout - we can hear you. It's on the end of central shaft. You will see it when you undo the three bolts and plate in the centre of the picture above. Tightening torque is 5nm. Manual says to use Loctite 243.
To put things in perspective - six clutch failures, one may have been due to the oil jet and the other five due to excess slippage. These may have been exacerbated by incorrect cable adjustment.
DID YOU READ THE BIT WHERE I SAID I WOULD SHARE INFORMATION?
( phew, breathless..)
I don’t want to post copyright material on here, but if you PM me I may be able to help
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