KTM 200 XC-W Clutch Problem

[Cyclon3]

Hi Guys,

I hope someone could possibly point me in the right direction here - because I'm running out of ideas...

The problem I'm having is that the clutch is engaging at the last 2 -3mm of the clutch lever's travel (right at the end). And when the bike gets hot (Riding rocks, etc) then it gets worse)

I've done the following so far as attempts to address the problem :-

I've adjusted the lever.
I've replaced the Plates & Discs (They all in the right order).
I've replaced the Axial needle bearing on the end of the Push rod.
I've bled the system. (And am using the correct mineral oil)
I've checked the outer clutch basket for grooves, and filled the edges smooth (less than 1mm was removed in bad spots)

The clutch is not slipping or shuddering ... just taking very late.

Anyone know what the cause could be?

Thanks in advance!

 

[split484]

possibly gear oil...or whatever you have in the transmission case that's also lubricating the clutch

 

[TCTrailrider]

Are you back bleeding? Sounds like air in the line.

 

[agitt73]

my front brake dose the same thing and its brand new
maybe an hour of time on it

 

[mx835]

Really does sound like air is still trapped somewhere

 

[mideastrider]

I'm not sure what's in the XC-W. But I know the SX and XC has either 2 or 3 aluminum plates in the clutch stack the rest are steel. These aluminum plates go away fast. That makes the clutch engage and disengage way late. I know lots of riders that ride the 200 remove these and replace with steel as soon as they get the bike. An 06 bike with the stock metals, i'll bet the aluminum one's will be out of spec by close to 1mm.
Just something to check.

 

[two-stroke]

i've had similar problems. check the line where it attaches to the reservoir
my clutch always started out strong and faded with use, just look over the line from the sounds of it it's a very small hole