CLUTCH WEIGHT

Installation Guide: Clutch Weight

Tools Required

  • 8mm socket
  • T-handle or ratchet
  • Torque wrench
  • Brake cleaner/rags
  • Medium thread locker (blue Loctite)
  • Pick or small screwdriver
  • Rubber mallet (optional)

Step 1 — Lean Bike Over

Lay the bike gently onto the left side (shifter side).

This prevents engine oil from pouring out when the clutch cover is removed. You only need about a 45° lean angle.

Step 2 — Remove Clutch Cover

Remove the clutch cover bolts carefully.

Keep track of bolt lengths because some KTM covers use different bolt sizes.

Gently tap the cover if it sticks.

Step 3 — Inspect Inner Cover Plates

Some newer KTM/Husky/GasGas models have thin steel sound-deadening plates inside the clutch cover.

These may need removal for clutch weight clearance.

Check:

  • Does the clutch weight sit higher than stock?
  • Is there any possible contact with the cover?

If unsure:

  • Test fit cover later
  • Rotate engine slowly by hand
  • Look for rubbing marks

Step 4 — Remove Pressure Plate Bolts

Remove the 6 clutch spring/pressure plate bolts evenly in a crisscross pattern.

Do NOT fully remove one bolt at a time — loosen evenly to avoid warping the pressure plate.

Once loose:

  • Lift pressure plate assembly slightly
  • Keep track of spring washer orientation

Step 5 — Note Spring Washer Position

On DDS clutches there is usually a marked spring retainer washer with positions:

  • 1 = softest
  • 2 = standard
  • 3 = firmest

Stock is commonly position 2.

With heavier clutch weights:

  • Many riders move to position 3
  • Helps reduce clutch slip

Take a photo before disassembly if unsure.

Step 6 — Install Clutch Weight

Place the clutch weight directly onto the pressure plate assembly.

Align bolt holes carefully.

Apply:

  • Small amount of blue Loctite
  • Tighten evenly in stages

Step 7 — Torque Bolts

Tighten bolts gradually in a star/crisscross pattern.

Do not overtighten.

Use KTM factory torque specs if available for your model.

Step 8 — Clearance Check

Before reinstalling cover fully:

  • Rotate engine slowly by hand
  • Listen/feel for rubbing

If rubbing occurs:

  • Remove internal steel noise plates
  • Carefully clearance offending areas

Some 250/350 models require slight trimming inside cover.

Step 9 — Reinstall Clutch Cover

Clean gasket surface.

Refit:

  • Cover
  • Bolts
  • Tighten evenly

If gasket tears:

  • Replace gasket before riding

Step 10 — Test Ride

Start bike and check:

  • No abnormal noises
  • Smooth clutch engagement
  • No cover rubbing

You should notice:

  • Smoother low-end power
  • Less stalling
  • Better traction in technical terrain

Helpful Tips

From KTM owners and mechanics:

  • Keep everything extremely clean
  • Take photos during disassembly
  • Use a manual for torque specs
  • Do not rush the install