KTM 250SX DDS clutch setup issues

JMX82
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JMX82
Edited Date/Time 4/19/2021 5:32am
My 2016 250SX started to suffer slipping clutch and I bought new clutch plates for it. The problem is that I can't get belleville washer tension set up according to manual spec. According to manual the belleville washer should be curved 0...0,1 mm and mine is 0,4mm in z-position with the new clutch plates




I was thinking replacing one 1,4 mm intermediate disc with 1 mm intermediate disc from my old clutch pack to achieve correct belleville washer tension. Has anyone else had similar problems?


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rjg
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rjg 4/12/2021 12:14pm
4/12/2021 12:14pm
Before getting too worked up about it, I'd put it together with the setting that applies the least amount of preload. Then try it out and go from there. - I noticed enough of a cange when I adjusted preload position.
JMX82
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JMX82 4/12/2021 12:25pm
4/12/2021 12:25pm
rjg wrote:
Before getting too worked up about it, I'd put it together with the setting that applies the least amount of preload. Then try it out and...
Before getting too worked up about it, I'd put it together with the setting that applies the least amount of preload. Then try it out and go from there. - I noticed enough of a cange when I adjusted preload position.
It's now in position with least amount of tension. I tried it with other positions and the curvature was even greater with those
JMX82
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JMX82 4/13/2021 12:48pm
4/13/2021 12:48pm
I replaced one 1,4 mm intermediate disc with 1 mm disc from old clutch pack. Now the belleville washer curvature is 0,1 mm which is within the service manual spec.


rjg
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rjg 4/14/2021 11:28am
4/14/2021 11:28am
Try it out and see how it operates

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JMX82
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JMX82 4/18/2021 11:33pm
4/18/2021 11:33pm
JBoneMotorworks wrote:
Install one from the 450sxf of the same yr and check it again, better clutch action that way too.
I assume you are talking about the belleville washer. I did cross reference between 250SX and 450SX-F part numbers and 450 seems to have different part number for the belleville washer. I might try that at some point

250SX:


450SX-F:

JBoneMotorworks 4/19/2021 5:09am
4/19/2021 5:09am
It is a diff part number but an upgrade to a more hd clutch mod.. did that to many 250sx and had great hookup.
2
sandman768
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sandman768 4/19/2021 5:32am
4/19/2021 5:32am
JBoneMotorworks wrote:
It is a diff part number but an upgrade to a more hd clutch mod.. did that to many 250sx and had great hookup.
Heavier clamping pressure?

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