Clutch Booster replacement


Borrowed use of impact driver and extra pair of hands on saturday (thanks DSM8) to replace the clutch booster.

Outer cover and cap removed.
Yer lookin' at the clutch booster assy.

Hey look! There's oil in there. Inner basket area was dry when I had it appart a few days ago. Cleaned oil jet is making a difference.

Booster assy removed.
Clutch cap attaches to the outer ring (left).
Inner hub (right) is splined to the transmission.

Worn ramps on the inner hub.
Seats in the outer ring were equally hammered and elongated.

Installing new booster with assembly lube at the contact points.

Took the opportunity to check the clutch discs. They all looked fine except for one side of one friction disc (3rd from back) was blackened and worn. Mating metal disc was fine, so nothing to do but clean, oil and put it back in.

The cleaned out oil jet got rid of the grabby, chattery cold clutch action. The new booster assy tightened up the entire transmission / drive-train feel. I would describe it like the difference between an old, stretched out, loose chain and a new, properly adjusted chain. Very happy

The Clutch pressure booster is KTM Part No. 600.32.080.000
Special tools:
Clutch locking bracket p/n 60029003000 and engine blocking screw p/n 0113080802

Rider914's clutch jet cleaning proceedure

Fairly easy procedure ( <20 minutes).
S/B done every 15,000 km

Cap and oil jet are hiding behind the c/s sprocket cover.

Sprocket cover, case guard, and clutch slave cyl out of the way.
Ready to remove oil jet cap.

Hi-tech oil jet removal tool.
Jet came out easily, maybe cause the engine was hot.

The clutch oil jet.

Jet seemed to be clogged with mud. Couldn't see any light thru it until poked with a toothbrush brisstle and blown out with carb cleaner

(ed. ADVrider Thread)

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