KTM DDS Clutch Inspection & Replacement 

Probably the best how-to videos in RU-vid as far as KTM goes. Slavens Racing is good, but I think Tokyo Offroad has him beat. Excellent, your best video to date.

And yet another great video going into my "KTM maintenance" folder...Excellent.

I did my first top end rebuild watching your videos and now I’ll be attempting my first clutch rebuild watching your videos! Thank you for the time and effort you put into these!

So refreshing to see a video like this that pays attention to important details. Thanks Tokyo Offroad!

The best instructional videos for maintaining a KTM. Great job!

Replaced my clutchpack today using the detailed procedure here. The info about checking the spring plate flatness primed me for when I discovered it was concave with the new plates, and I immediately knew what to do to rectify it. Spot on! Excellent video. (Also a member of Kansai Riders)

some of the best instructional videos going cheers Tokyo Off Road👍

I love the attention to detail on your video. Makes rebuilding clutch packs less intimidating

Thank you for taking the time to do this. Very good instructor!

Thank you. This video increased my confidence. And I must say, WOW what a difference the new ones made. I just bought a ‘21 sxf 450 and had heard about this maintenance item so I ordered the Rekluse set figuring it may be due. So much smoother, quieter and best of all, no more chain slap rolling through the pits!! The chain slapping around was ridiculous.

Damn boy! you are seriously detailed! You are the kind of person that would be working on my factory edition 450sxf. Good Stuff!

Love your no-nonsense instructional videos! Best I've found for my KTM.

Thanks for the video. I never did that style of clutch before and I just bought a 2018ktm xcw 6 days. So the clutch design is very different than my 2008 KTM 200 Xcw.

Just done this :) great help thanks, on this 250tpi 2018, one of the dampers had actually broken and worn right down uneven on one side!!

Excelente video! Muy claro y útil. Gracias por compartirlo. Un saludo desde Argentina!!!

Thanks a million. All worked out perfectly. Appreciate the attention to detail. Even going make a tool from the old clutch plate...👍🙏

Great video and very informative as usual, however it’s extremely difficult to take anything you say seriously after I watched your best modification video. My favorite was the power band! Please keep up the great vids.

Awesome video - when I am going to change my clutch (which is soon), this will be my guide :-) Thank you.

Another great tutorial, thanks for putting time into these videos. I rebuilt my top end recently following your top end video, very helpful thank you. Can you make a video on how to clean a bike properly. With 160 hours on your bike and mine has sixty mine looks like it's done 560 compared. Your swing arm looks new, mine is all stained from mud, same with my hubs. The best videos on RU-vid for riding and mechanical tutorials. Awesome work cheers from Australia.

Best and most detailed videos. Thanks a lot for this from Brazil! Will help me rebuild my Husaberg TE 300 2013 clutch

Nice vid I liked your cardboard template for the bolts ,I have 2 x 2007 450 sxf engines which we retrofitted the dds clutch into ,I really like this clutch over the earlier conventional spring clutch .cheersd

One of the best video for ktm... Hope you make rebuilding the engine👊👊👊

well done, 3 of my dampers were broken in two. the other 3 were spread out, lots of play. easy fix.

Thanks this was very helpful to watch before attempting myself. Few minor differences on my 2020 500 EXC-F. Manual says torque is 80NM and no loctite. Everything else was pretty much the same.

Your videos are fantastic, thanks for sharing them.

thanks for the good video! i need to do this today to my 300 tpi :)

Make note: clutch cover bolts, there are long sizes there. The shorter of the longer clutch cover bolts goes in by the starter. If you install the long one there it will not tighten the clutch cover. It bottoms out on the outer cases of the starter area. Learned that the hard way.

@ minute 20:36 I've got the same kit for my Husaberg 2013 Te 300. I've measured the metal disks and found: 4 disks with 1.3~1.34 mm and only 3 with 1.4mm. I wonder if that's just a fabrication variation. I've mounted the internal 1mm with the "S" mark as you mentioned, then 2x 1.3mm, then 3x 1.4mm in the middle, the other 2x 1.3mm and the top 1mm disk. Tested the bike this weekend and worked just fine. Great channel, great videos! Best regards from Brazil!

I had dampers break from heat cycles in ktm that only had 40 hrs....good job Mark

Excellent video. If I done this I could follow your video the first time and breeze through the job

i like how u work, really nice

Just used the video to replace my clutch and now it's working perfect! thanks Mark! :)

Very well explained all along, with specs and tricks.

Your videos are veery therapeutic :D thank you for great information here.

Learned quite a lot. Very concise and easy to follow. 🎯

Excellent. Thank you for a great instructional video.

Great tutorial, it guided me through the process. Thank you 👍🏾

Thank You Sir for your time, this video is perfect, very well done, congratulations. Best regards.

Excellent video , nicely done !!

Brilliant video as usual. I have lost count of the amount of times I have referenced your videos while working on my bike. One question. What is the thickness of the fibre plates when new. To see what loss you occurred with them all reading about the same on inspection. Thanks

Thanks for the video! My new clutch set has three 1.3mm metal plates. What's the logic for putting these thinner ones to the inside? Thanks

excellent video. thanks for posting.

Thank you for the videos you make Sir !

My kit had 3 metal plates, too. But not in the same quantity as yours. I put my thickest plates in the middle, as my worn pack was the worst there. More metal = more heat capacity, I figure. So they're setup as 1.0-1.3-1.3-1.4-1.4-1.4-1.3.-1.3-1.0.

thank you, best video replacement for sure!!!

I didn’t pay any attention to the difference in steel plates thickness when I replaced mine, seems to be working. What happens if the steels are in wrong order (thickness wise)?

Thanks a lot for this. Really well done video.

How do i get one of those fancy Tokyo off-road oil drain tools? Looks like a compression tester fitting 😃.

Interesting my OEM kit for my 2017 TE250 came with One 1.0mm S, Three 1.3mm, Three 1.4mm, and one 1.0mm. I wonder if they have updated the pack since you made this video. Measured with calipers and clearly shown different then your video

Great video thank you for being so thorough

i checked my spec on the belville spring it was around 0.35mm so out of spec, i have pulled the clutch apart to replace but the clutch plate thickness is basically identical to the brand new set ! , maybe i just need to change the belville spring to get the correct tension back onto the plates ?

Great videos, keep them coming.

What kind of effect can loose rubber dampeners have on the bike? I just ordered a new set as mine are loose themselves. The bike feels like the clutch is dragging at mid-to-top end. After inspecting the clutch, this was the only item of notice.

Really satisfying see u work 👌

Excellent very well explained thanks

Great video. Just one question. Should the clutch throw out shaft have a rounded end on the clutch side ?

Great tip for the bolts in the cardboarb👍

so the adjustment on the belvil spring tensor would stop my clutch from being so grabby ??

Nice explained ! But still rubber for the damping ? My BSA from 1968 had also rubber dampers , and on 4000km they must be replaced ! Nothing has changed !

Very great video, when I inspect my clutch pad, it's still more than 1.9mm, but it weared somehow forsure, should I move the bolt from position 2 to position 3? I think the clutch disk get thiner, thus the spring preload might get ligher in the same position. Am I correct?

Great video Mark !

Brilliant video.

Great video as always - used it to inspect and change my first clutch on my '16 300XC. Interesting that although my metal discs measured 1.0mm on the inside and outside, the four discs (going inside to outside of the bike) after the "S" disc measured 1.3mm, and the remaining four discs measured 1.4mm. My bike has less than 75 hours on it, but it has started slipping suddenly. The friction plates look good and appear to have little wear. The middle-metal plates are hued purple, and most of them show somewhat heavy wear marks. Sliding aside the rubber boot next to the clutch master cylinder, I noticed either corrosion or dried fluid. Any idea which of these could be responsible for the slippage?

Hello love your vids could u tell me were do u get the we dampers from I'm goin 2 put a new clucth in my bike an want 2 put new dampers in 2 like u hav done here thanks.

Fantastic demonstration

Would the fiber thickness be the same on a 19 300i xcw? I just pulled my plates and the inner ring on the steel plates are black, fiber plates are 1.55-1.79mm thick. Can’t find the spec in my manual

First I have to say great Video!! Helped me a lot... I have a 300 EXC 2015. Clutch is not 100% the same as yours but Looks similar. I done everything like you explained it in you Video.. but if I Pop the clutch for a wheelie as exaple it Slips... checked several times... changed the Spring from y to x and z but it won't get better.. Maybe you have an advice for me..

Do U have schematic print out on ur homemade clutch tool for ktm 15 xcw 300 ? Or do U sell them. Great video by the way.tks

What is the concern with the discolouration? Worried about it becoming brittle or warping? Looking at mine and likely coming up on needing to change the clutch pack. Great informative video!

Im thinking about doing this with my own 500 exc 2016 with your video as a guide. If my plates is not the same thickness as yours, should i just go from thin to thick? Lovely video btw!

Great video! Which setting (1,2,or3) on the Belleville spring makes the clutch pull the lightest?

My clutch steels has 3x 1.3 plates and the rest 1.4 do they still go in first

Nice video again! Is there any different feeling after changing the hub damper? Is there any way to know the wear of them before dissemble the basket?

Is this the same for those of us with the Rekluse?

Where can i get a set of foot pegs like the ones you have on?

Job well done!

Cant find the spec for the plates for my ktm exc 125 i have the manual

Hello, you dont know, but you helped me a LOT. I was wondering if you know what is the difference with starting plate marked with S and the last one, both 1mm but different part number. Thanks Greetings from Slovenia

Advise Please! My KTM 2018 xc-w clutch drags with the clutch lever fully pulled in to a point that if you lock up the rear it sometimes kills the engine. Thanks for all your videos. Peter

Have you ever went to the point where the clutch started to slip ? Im just changing mine and will put in new rubbers from Recluse too. It has 265 hrs on it and still feels good, maybee a slight more drag than new. Im riding tecknical enduro and slip it a lot.

For the 1, 2, or 3 setting on the spring, is this adjusted by the factory for a specific bike, or can you change the setting based on preference? Such as using a lighter setting if you don't demand as much instant torque?

Can I use Loctite 243 or 2701 instead of the 648, which I can't find?

Would bad damper's cause a knocking noise at idle with clutch out?

fantastic vid is it the same on 500 4t?

Cool Vids! Something to keep in mind...apparently the furthest inside and outside Drive Plates (obviously only 2) are about .96mm thick, and the inside Drive Plates are approximately 1.3mm thick...might ck with digital caliper, just in case the pack is removed in multiple layers.

Weird that on the 2012-2016 250/300s it says to use 10nm on the clutch spring bolts and the clutch cover bolts and on the newer ones it says to use 6 and 8. I just stripped one of my clutch cover bolts either because of the 10nm or it was the wrong length. Edit: So it turns out all of the bolts are supposed to stick out the same amount when fully unscrewed. One was really far in and one was far out. I switched them around and it worked fine, I tightened them to 8nm and the one I stripped had enough thread further down to hold that one. After I had stripped it the first time I would've left it except the bottom of my clutch cover was leaking oil.

Great video, I’ve just done my clutch rubbers but my clutch still sounds very chattery when clutch lever is out. Should there be rotational play on the clutch basket? Any help would be appreciated, or are they just noisy

Hi Mark! how are you? nice video! which are the possible failures or problems if your dampers needs replacements on the hub?? you show the hub has some play...what can happen if that occurs?

Best RU-vid

Outstanding! Thank you!

@tokyooffroad Can you point me to a good place to find clear instructional video like yours for an older 4T KTM? 2010 450 XCW SD Can't find any help anywhere. I believe those clutches all the same 2008-2012?? Pre-DDS. Do you have a video of such? Thank you for your consideration. I give you a 5star 10 out of 10 rating over others I have compared. Slavens is not as good!

Thanks for the video! My manual (16 500EXC) says 80Nm (60ftlbs) for the clutch basket .... not 100 and no loctite

When you talk about the sharp edge and the smooth edge of the steels, if you get one wrong, what would happen? I know I got my "s" plate in and faced correctly but am not 100% on my steel plate placement. After I replaced my clutch dampers and re-assembled, the clutch is working great. Is it worth inspecting again? Thanks!

Mark, I am rewatching the vid as I have problems with my clutch slipping for the second time - each time after approx 60 hrs the clutch was toast. I see in your vid, when you put the pressure plate it doesnt wobble. Mine does wobble (there is 0,5-0,8 mm gap between the pressure plate and last metal plate...and I wonder why that is - i was suspecting some bubbles inside my clutch line but I think I bled them out...really strange...and all the plates are within spec...

Can this clutch be retrofitted to pre 2012 bikes? Is it any quieter? It seems some of the smaller newer bikes use a non damped version of this basket

On a 2014 or older ktm 300 xc has 250 bellville spring, would you recommend 280

I used the clutch overhaul kit and when I finished fitting the spring was convex from the engine side, what should I do? I tried all 3 screw positions but nothing has changed

Just found your channel. Have you ever done a complete motor rebuild video? Would be a great help of what all goes into it since KTM is very particular and uses a lot of special pieces unlike other bikes.

Great video, Thank you!!!

How do you know all these small details? I have owners manual and even bought repair manual as well but there is no information about direction of plate "S" and other plates with sharp edges up etc. etc.