clutch problem

05 superduke 12000 miles crunches when selecting gear. Bled the clutch with the correct fluid, no air found, checked slave cylinder no problems. Took to garage they’ve replaced the plates in the clutch hardly any difference.

The problem started a week ago when I noticed when it was put into gear with the clutch in it was creeping forward adjusted clutch lever out and carried on but then noticed the crunching, is it likely that I need to replace the complete clutch, there doesn’t appear to be any other wear on the clutch.

Any advice would be appreciated

Did they tell you why they replaced the plates?

SD clutches are pretty tuff but also quite fussy about being changed as a complete unit, ie. all discs and plates.

Also what oil is the bike running?

Maximus has a problem so i said id post it on here while he is out scrubbing clutch plates!!!!!!!!:



My 06 SD has developed a nasty clunking,grating when going into 1st. i know a lot seem to do this but mine sounds particularly nasty.

I tried replacing slave for an oberon but no improvement, refitted old slave just as bad (both were bled to death and the little steel ball was in place)

I have measured the clutch plates and springs and all seem above the minimum tollerances.

Any ideas would be appreciated

Cheers chaps

bent/worn shift-fork?
do you ever get 'kicked-out' of gear?

Dont think he gets kicked out of gear, I looked at it yesterday and seems to be just getting it out of Neutral is the prob

Cheers Si,

No it never seems to kick out of gear, it just feels like the clutch is dragging or just not engaging enough.

it almost feels if the slave is not throwing enough but ive tried 2 slaves (oberon and standard) bled them to death, with no difference.

Its gonna be a box of matches soon

Take a look at this thread: viewtopic.php?f=5&t=16211
Hope it helps!

Thanks Bert, ive been on it all day, ive cleaned the jet out, still no difference.

It definitely seems to be dragging, i put it up on paddock stands put it in first and pulled clutch in had to use a boot to stop it spinning then it picked up speed again quite quickly.

not sure what to try next ?

Something strange happened to my 06 SD's clutch last night when I was arriving home from a short ride. I was slowing down and changed the gear from 2nd to 1st and the shift felt harder than normal. When I parked the bike in front of my house I noticed I could not get it to neutral. The gear lever feels very stiff and the bike crawls forward heavily when the clutch lever is pressed. It seems the problem is that the clutch does not disengage fully anymore. Any idea what might have broken down?

Id say your clutch needs bleeding as is leaking and may need a new clutch slave cylinder (if it is go for an Oberon) sure someone will chime up to confirm, deny or clarify this.

I'm thinking the same as superdan. The piston in the clutch slave is probably jammed.
Take a look at this thread: viewtopic.php?f=5&t=17649

I also recommend an .

Thanks a lot for your help guys I really appreciate taking your time with my problem!

I took the bike to the shop where I bought it and they spend an hour inspecting it, bled the clutch fluid etc but it didn't help. They now also think it's the clutch slave that is not working properly. I've now ordered a new clutch slave trough my local KTM dealer. The Oberon unit looks like the best option, but I want the bike up and running as fast as possible so I settled with the OEM replacement that I can get through the dealer within a few days. I really hope the new slave cylinder fixes the problem.

I did a lot of searching on the forum and this guy describes my problem exacly:


So I came to think it might not be the clutch slave after all but I guess I see after I replace it.

The old clutch slave is not leaking at least because I haven't lost any clutch fluid so that's not the problem. If the piston is jammed should I feel it somehow trough the clutch lever? I would think perhaps the lever would be stiffer, not move all the way or something. And if the piston is jammed can it be somehow unjammed or is the new clutch slave unit the only option?

Today I had some more time to investigate the problem. I took the clutch slave sylinder assemble apart and noticed something strange. I'm no expert at these but is the seal under the sprocket cover that holds the push rod pin supposed to look like this?? I mean it looks a bit strange because it's not symmetric.



To me it looks like this could happen. The metal even has some marks on it that this has defilitely happened at some point. This would cause the push rod to move only slightly an make the pin stop it movin all the way:



In comparison here's how it should look when the rod is fully pushed. You can see the marks on the left side of the hole.



Is this normal or is there something fishy going on here?

Anyone?

Also is the pressure booster in the clutch basket supposed to be loose? Like moving up and down about half a centimeter?

Thanks for your help!