2008 KTM 125 SX
Question
Help! I have a 2008 KTM 125 SX. Recently, I installed a new top and bottom end. Everything went back together smooth, but now the clutch will not completely disengage. Prior to the rebuild it was a little squishy, but now it’s much worse. I rebuilt the master cylinder and the slave cylinder, used all new fluid and I’ve bled it every way possible. It’s gotten a little better but it’s far from good. Any suggestions??
Answers ( 6 )
Did we forget a washer in the throw out assembly ?
The slave gasket is available in three different thicknesses (0.3, 0.5 and 0.75 mm). Perhaps try a thinner gasket?
The little ball bearing that goes inside the slave Rod is missing
Rebuilt the bottom-end on my son’s 105SX a few years ago. Similar symptoms; turned out to be the clutch hub nut was over-torqued, even though I used a torque wrench set to service manual specs. Service manager figured it out. I never would have guessed it.
Did you try bleeding with a syringe from the bottom up? The thinner slave gasket mentioned above is a great idea if it’s led correctly and still has issues.
I just ran into this in March and in my case it was the hub nut torque