'23 KTM 250 SXF - baffled how to remove inner clutch cover

DirtBikeKid46
Profile picture for user DirtBikeKid46
Posts
239
Joined
12/21/2015
Location
Philadelphia, PA, USA
DirtBikeKid46

Worked on many of these bikes but the new gen I have yet to replace a timing chain. Attempting to remove the inner clutch cover and the bottom left side is pinned between the engine and the frame only allowing about a half inch of rise before it hits the frame, the right side is held on by the water pump impeller shaft. Unable to lift it high enough to get off. I can't imagine they designed this to be removed by removing the entire engine. Any suggestions?

66236624.jpg?VersionId=PKqzT4oXX.bUC4IISxSEC68E36Vtk6625.jpg?VersionId=dh2LykSX7QqLuLg5C5NctPoFY96626
|
Factor E
Profile picture for user Factor E
Posts
978
Joined
9/22/2011
Location
So Cal, CA, USA
Factor E 4/22/2026 8:37pm
4/22/2026 8:37pm

U have to pull swing arm bolt and lift motor up avout 2 inches to remove  Once all mounts are off I use 2 tire irons in between the frame and motor to hold it up

DirtBikeKid46
Profile picture for user DirtBikeKid46
Posts
239
Joined
12/21/2015
Location
Philadelphia, PA, USA
DirtBikeKid46 4/23/2026 6:44am
4/23/2026 6:44am
Factor E wrote:
U have to pull swing arm bolt and lift motor up avout 2 inches to remove  Once all mounts are off I use 2 tire irons...

U have to pull swing arm bolt and lift motor up avout 2 inches to remove  Once all mounts are off I use 2 tire irons in between the frame and motor to hold it up

Thank you! I had no idea you have to go through that to pop the inner clutch cover off.

Factor E
Profile picture for user Factor E
Posts
978
Joined
9/22/2011
Location
So Cal, CA, USA
Factor E 4/23/2026 4:55pm
4/23/2026 4:55pm

While apart check your shift arm for rounded points that grab the shift star pins. if questionable replace now they will cause mis shifts

Post a reply to: '23 KTM 250 SXF - baffled how to remove inner clutch cover