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What type of clutch for Motard (KTM 520 SX)

  1. #1
    Lifer Ductard's Avatar
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    What type of clutch for Motard (KTM 520 SX)

    I think I might need a new clutch on my motard. Might just need an adjustment...not 100% sure, b/c I noticed it the session before I had to jump into a (still in-progress) top end rebuild.

    I'm thinking about ordering the parts just in case (bonus if I get them off amazon.com 'cause I can send them back for free if I don't need them).

    That said, I have no idea about brands or what material to get (esp. since the OEM dirtbike clutch might not be the best for roadracing).

    Any thoughts?

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    Lifer lrrs313's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    OEM. I had the best luck on my KTM SMR with OEM stuff. And there's no adjustment on a KTM clutch, the hydraulic system is self-adjusting.

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  3. #3
    Lifer Chippertheripper's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Cliffs is almost guaranteed to have what you need in stock.
    Not only will they get you into the RIGHT stuff, they can mail it right to you, if'n ya can't make it over there.
    As for brand, stick with the OEM...
    My one question is, why do you think the clutch is smoked? It's not like you use one on a MOTARD at all.

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    Soul Rider Paul_E_D's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Slipper. LOL

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    Lifer union's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    The type of clutch depends on the type of riding.

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  6. #6
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Chippertheripper View Post
    Cliffs is almost guaranteed to have what you need in stock.
    Not only will they get you into the RIGHT stuff, they can mail it right to you, if'n ya can't make it over there.
    As for brand, stick with the OEM...
    My one question is, why do you think the clutch is smoked? It's not like you use one on a MOTARD at all.
    Well, the clutch *was* slipping on the last session at NYST before I took off the top end.

    The reason I'm unsure, is that that little plastic adjustment nut came off of the clutch lever...and the clutch is hitting the handguard before it can fully extend.

    That is the likely culprit, but I wanted to head up to R7 with some certainty - with shipping times etc. I'd need to order one today or tomorrow, unless a place like Cliff's had it in stock.

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    '12 Ducati 1199 Panigale (track) '08 Honda CRF 250 (ice) '02 KTM 520 SX Supermoto (track)

  7. #7
    Lifer Chippertheripper's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Call in the morning. Your levers aren't adjusted so that the handguards don't interfere? Something is amiss.

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  8. #8
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by union View Post
    The type of clutch depends on the type of riding.
    Do you mean it depends on my riding style? Cause the type of riding will be roadracing...with maybe some ice-biking this winter...but optimized for roadracing in every respect if there were to be a difference in the two.

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  9. #9
    Lifer union's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Ductard View Post
    Do you mean it depends on my riding style? Cause the type of riding will be roadracing...with maybe some ice-biking this winter...but optimized for roadracing in every respect if there were to be a difference in the two.
    For road racing I would want a slipper clutch. hit the brakes jam down the gears. Not so much for dirt or ice riding. I like a bit more engine braking for that.

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  10. #10
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Thanks, that's helpful.

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    '12 Ducati 1199 Panigale (track) '08 Honda CRF 250 (ice) '02 KTM 520 SX Supermoto (track)

  11. #11
    Soul Rider Paul_E_D's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    I know you weren't asking this, but slipper all the way. Even on ice it's better IMO! We will spend all of your money yet.

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  12. #12
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Paul_E_D View Post
    I know you weren't asking this, but slipper all the way. Even on ice it's better IMO! We will spend all of your money yet.
    Dammit.

    I spent half an hour yesterday looking for a used slipper on eBay...not sure if that's something you'd want to pick up used but wanted to see if there were any to be had...

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  13. #13
    Soul Rider Paul_E_D's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Definitely available used. I bought one for my triumph used. Half price and zero wear on it.

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  14. #14
    Soul Rider Paul_E_D's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    But i would search supermotojunkie, not ebay

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  15. #15
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Paul_E_D View Post
    But i would search supermotojunkie, not ebay
    Thanks Paul, looks like I just missed one on there from a big 3 bike KTM part out a guy was doing.

    Was asking about tree fidy for one.

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  16. #16
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    Re: What type of clutch for Motard (KTM 520 SX)

    Slipper works best for mine.

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  17. #17
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Paul_E_D View Post
    But i would search supermotojunkie, not ebay
    Just cross-posted this on supermotojunkie, but thought I'd put it up here and see what people thought.

    I started off a while ago looking for a used slipper clutch for my '02 KTM 520SX, couldn't find any so I finally broke down and started looking for a new one.

    I can't seem to find any that are made for an '02. A lot of them fit '03 to '08(If I recall).

    I've looked at some of the engine drawings to see if the clutch has the same part #, but some of them are the same (I think I was looking at 520 sx vs. '03 525 SMR), some of them are different, and I don't know enough about clutches to know which part numbers are relevant.

    Any insight here?

    ...also setting the over/under at 1 hour and 45 minutes before Chipper posts that I should just call Cliff's :-p

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  18. #18
    Ahh why not! lrrs428's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    No slipper in my A or B bike , straight up is the way to go, only my opinion

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  19. #19
    Lifer Kurlon's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Is the main shaft different between the 02 and 03? At the very least your machine can be updated to match the later RFS setups, but it might get... spendy.

    So, yeah, main shaft is different, but the gears on it are the same. $100 for that, plus whatever OEM clutch bits are retained with the slipper that differ between the two years. Oh, and you're splitting your cases to swap main shafts.

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    Last edited by Kurlon; 03-19-15 at 03:52 PM.

  20. #20
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Kurlon View Post
    Oh, and you're splitting your cases to swap main shafts.

    I'm guessing you've got a good memory re: my aversion to case-splitting. I'm looking to get over that and do a bottom-end anyways. :-)

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  21. #21
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Kurlon View Post
    Is the main shaft different between the 02 and 03? At the very least your machine can be updated to match the later RFS setups, but it might get... spendy.

    So, yeah, main shaft is different, but the gears on it are the same. $100 for that, plus whatever OEM clutch bits are retained with the slipper that differ between the two years. Oh, and you're splitting your cases to swap main shafts.
    ...Assuming it's still got the stock main shaft in it to begin with. I know it's got some bottom end bits swapped out already (i.e. 6 speed tranny vs. the stock 4).

    There's a chance that Mike slipped a different main shaft in there when nobody was looking. By most accounts he's pretty tricky.

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  22. #22
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    Re: What type of clutch for Motard (KTM 520 SX)

    Surprised there's not more on the market. There used to be tons floating around. Maybe call Motostrano? They may be able to tell you what cross-references.
    The bottom end is stock with the exception of the Falicon supercrank treatment (stock crank trued, welded, knife-edged, etc).
    A new set of crank bearings is always good insurance if you're in there, but you need some special tools to get the races off and then a dial indicator to measure axial play. Not too hard, just tedious. Other than that splitting RFS cases is easy. Just run it through the gears before you move on to the top end.

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  23. #23
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Tricky Mike View Post
    Surprised there's not more on the market. There used to be tons floating around. Maybe call Motostrano? They may be able to tell you what cross-references.
    The bottom end is stock with the exception of the Falicon supercrank treatment (stock crank trued, welded, knife-edged, etc).
    A new set of crank bearings is always good insurance if you're in there, but you need some special tools to get the races off and then a dial indicator to measure axial play. Not too hard, just tedious. Other than that splitting RFS cases is easy. Just run it through the gears before you move on to the top end.
    Thanks Mike - super helpful as always.

    What do you guys think of a hot cam Stage one as a $125 investment while I'm in there?

    That bike has low end in spades, wouldn't mind a little more peak HP - even if it meant giving up a little torque.

    Setting aside tuning /rejetting that it would need, is there anything else I should be concerned about? I.e. am I starting to get into the types of mods that make these motard motors pop left and right?

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  24. #24
    Lifer Ductard's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Quote Originally Posted by Tricky Mike View Post
    Surprised there's not more on the market. There used to be tons floating around. Maybe call Motostrano? They may be able to tell you what cross-references.

    Quote Originally Posted by Motostrano
    Hello Jeff,


    After doing some digging we are not going to be able to source a slipper clutch for that bike. None of the vendors we work with have any applications for the Pre 2003 Models. If you need other parts we should be able to help you.


    --
    Frank Bravo
    Motostrano.com
    926 Broadway St.
    Redwood City, CA 94063
    650-918-6259
    ....Damn.

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    Last edited by Ductard; 03-27-15 at 11:11 PM.
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    '12 Ducati 1199 Panigale (track) '08 Honda CRF 250 (ice) '02 KTM 520 SX Supermoto (track)

  25. #25
    Lifer Kurlon's Avatar
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    Re: What type of clutch for Motard (KTM 520 SX)

    Main shaft swapping time.

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