By: SS in Vzla
The manual says it should be done every valve check (15.000 kms / 9.400 miles). But sometimes I do it at shorter intervals, whenever I find my clutch is dragging too much. After the first time, it is a very fast procedure that can even be done in the field without any hassle.
Start by removing the center sprocket cover (3 bolts)... Once the cover is off, the allen bolt that will give you access to the oil jet will be exposed. Since it is located in an area that tends to fill with chain lube gunk, I suggest you clean the bolt and it's surroundings with some kind of degreaser so nothing falls in the hole once you remove the bolt.
Note that the OEM c/s cover has a plastic tab covering the allen bolt. If you wish, you can grind the tab, leaving the bolt head exposed. This will save you time on your next clutch oil jet cleaning since you won't need to remove the c/s cover. I've done this to my bike about 25.000 kms / 15.600 Miles ago with no problems... the bolt will get dirty even with the tab on... YMMV.
Remove the bolt with the correct allen wrench... Beware there is a brass washer that should come out with the bolt. Don't loose it
Once the bolt and washer are out of the way, take your "Clutch oil Jet Special Service Tools" from your KTM tool case...
A bobby pin (with the round ends cut off) and a guitar string... The one pictured above is 0.08 mm thick. The (very tiny) hole in the jet is 0.30 mm, which means that any string will fit in there as long as it is smaller in diameter (for example 0.10 mm, 0.12 mm, 0.20mm) just use what you can get your hands on.
KOTH: The high "E" string on a guitar is usually solid and 0.25mm in diameter.
Next, it is a bad picture, but you can see the oil jet in the hole so you get an idea how it should look like... It's easier to see with the left side fuel tank off, but it is not necessary to remove it in order to clean the oil jet. If you clean the jet when you check the valves, you'll have the tank off the bike anyway.
The jet is screwed in place. Take a flat screwdriver and unscrew it. You will need a short screwdriver because the frame of the bike gets in the way if you use a long one... Some better mechanics than myself recommend using special gunsmith screwdrivers which I'm sure work a lot better, but I've had good luck with the screwdriver that comes in the OEM tool kit... Just be sure the screwdriver's head is in the appropriate notch on the jet's head, press on the handle with a downward force with one hand and turn the screwdriver (anti-clock wise...) with the other hand. Some jets are screwed in pretty tight, just take this in mind if yours happens to be one of the stubborn ones... It is normal, and as long as you keep the downward pressure on the screwdriver and the head properly nested inside the notch, you won't damage anything.
When you feel the jet is completely unscrewed, just grab the bobby pin, press the the points together and insert them into the hole located in the center of the oil jet's head, when you feel you cannot press any further down, just release the bobby pin's points so they open and pull the jet out. This might require a couple of tries and several choice words, so if you see yourself getting frustrated, just walk away, have a beer and return... It WILL be a lot easier with practice. Some people use a wooden matchstick which the press into the hole to pull the oil jet out. Some people use some chewing gum or putty, but I'd rather keep foreign objects out of the cavity...
The bobby pin works nicely once you get the hang of it.
And the oil jet is out!
On the next picture you can see the bolt on the right and the oil jet on the left... If you look closely to the oil jet's head, you can see a "30" marked on there. Some of the earlier 2003-2004 bikes have a plug in place of the oil jet... Reference to this plug was in a TSB and should have at some point been changed in favor of the 0.30 mm oil jet by your dealer, but if they missed the TSB and you happen to find a plug in there (i.e... there's no "30" markings on the head), it would be a good idea to replace it. Note that the whole is VERY small... If you do not see the hole, it does NOT necessarily mean you have a plug.
At this point, you might like to put the allen bolt back in place (sans the oil jet), turn the motor on and give the gas a few blips to clear any debris that might be in the hole... You should put the bike in neutral before you start it, since it will not go into neutral with the motor running without the oil jet in place....
If by any chance you decided to take the clutch slave cylinder off to give you more space to work, DO NOT engage the clutch lever!!!
Take the guitar string and clean the oil jet... Compressed air will do the trick also. Be advised the hole is VERY small, it is difficult to see with the naked eye unless you happen to have the light in the correct angle... That's why I prefer to use the guitar string. As long as I can pass it through the hole, I know it is clean of debris.
Once cleaned, just assemble everything up in reverse order. Be careful not to cross thread the oil jet when you screw it in. If you don't have a new brass washer to put under the allen bolt, I suggest you anneal the one you took out and re-use it.
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