Solution to damaged inner clutch hub

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Eucl1d said:
Yeah I think that's right and the reason others on the site have suggested shimming it. I didn't though and it's working just fine for me.
Click to expand...

I thought I'd pop back in here to revisit the kickstarter shaft popping out.

Twice now it's popped out at the very end as I'm replacing the cover. Severely pissing me off after torquing nut down, etc.

Bike is on its right side - I think that lessens the chances of incidentally popping out - but I don't get how after placing the clutch basket on, that's not enough to keep it in place.

You mention shimming - can you elaborate?

Thx.
 
canolman said:
You should be able to remove the seal in situ using seal picks, just be careful and take your time, I've done it a few times.
For the record I've used the KTM seal and a 1mm wider seal on my engines, both have worked fine. The only ones that failed early have been the stock ones.
Click to expand...
Drill 2 small 2mm holes in the seal at 9 and 3 oclock screw in 2 small self tapping screws into the hole and pull seal out with 2 sets of pliers
 

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