KTM's Magura Clutch - how to pull it apart... in reverse 

Mine just failed 3 days ago. The OEM backing plate is plastic and when deformed it leaks, so a lot of owners install the Oberon billet backing plate, it won’t deform and runs cooler (£28 or so). The o-ring naturally wears, they’re around A$18, and when the cylinder is too scoured many owners install the Oberon slave, but the German Sigutech is better (3 O-rings). BTW, I used fragrance free baby oil, it’s 100% mineral oil, low viscosity, and gives a really nice feel...plus it’s dirt cheap. Also, if people retain the OEM backing plate, torque the bolts correctly or it will deform, it’s only plastic (10 Nm on the 1190/1290 from memory).

Thanks, our video was helpful, greetings from brasilian KTM owners!!

Great tutorial mate, only change ive done on my 950 adventure and 990 SMT is to bleed the clutch slave conventionally, hose on the nipple and apply clutch lever just like brakes, less fiddly and easily done in the sticks using 5w fork oil, never failed me at all.

And as you pointed out at the end with the air bubble, Cable tie/secure the Clutch leaver in on the bar to get more out overnight... as the microbubbles come out of the fluid with the release of the pressure.

A timely video - I’ve got my 690 all stripped down while it’s cold out and I am going to be changing out the clutch fluid during reassembly - thank you...

You have reminded me that my ZRX needs all its hydraulic fluids flushed. So many projects to complete before springtime arrives, but I'll be glad to have the cold weather gone. :)

The slave cylinder disk/piston with the green seal is known to fail at the base of the short protrusion (spring side), where it creates a hairline crack from which eventually loses all the hydraulic fluid from the master cylinder. The permanent fix for my 2009 990 Adventure (and after two of these failing) was to go the Oberon slave cylinder way. It worked flawlessly and made it to 110K kms when I (sadly) sold that bike. In the market for another 990 atm. EDIT: Looking at your video it seems that your slave cylinder piston is an updated version of what used to be in 990s with extra material at the base. Ours was a straight cylindrical protrusion whereas yours looks like it's stepped with more material at the base. Lastly, there's a much better way to bleed the system than filling the slave cylinder from the top. Bolt the slave cylinder on but not entirely, leaving a small gap between the unit and the plastic baseplate behind it, then remove the bungee tube and fill the slave cylinder from its top while gently tapping the unit inwards to activate the piston, refill and press again until all air bubbles are gone. Then reattach the bungee tube and complete the bleeding from above (master cylinder side) by filling the reservoir, pumping the lever 5-10 times and keeping it in while cracking the bleed nipple open, repeat until the lever isn't spongy and all air has bled off the system.

As usual, entertaining and informative vid Nerb. Embarking on a round Australia trip on mine this winter. Currently 27k on the clock so might get that clutch seal checked while in for valve clearance.

Very good practical demonstration

Thanks for that👍 Just about to fix mine. 2015 1290SA

Best to push up to reservoir from slave bubbles will want to rise. Some of the caps allow DOT 4 or 5.1 brake fluids.

As soon as I heard the tool I subbed haha,.love it

My clutch lever on my berg stopped working altogether recently, new seals and all good. Mine has a nipple on the slave cylinder allowing fluid to be pushed up from the engine via a syringe. The seals at the lever went years earlier.

Just a thought but I think it would be a good idea to put a little Loc Tite on those bolts.

Thanks for the video. Do you know if that spare parts fits on a 990 Adv slave cylinder?

Buy a Oberon slave cylinder to replace the KTM garbage.

I've got fc 450 17 and a 19 model I just used an o ring out of my metric eBay kit. seems to be working. time will tell .

Thanks. Great video.

You've made an easy job very complicated! 😃👍

Hydrauliköl kupplung? ktm 65 sx 2003 Was wird das richtige Öl sein? Muss mineral Öl? Er ist blau, aber ich kenne die Marke nicht 😕😔

Should only take KTM 10 years to acknowledge the problem & about 15 years to fix it.

Love your work Nerb1! You're KTM (the new model) is up there high on my list of bikes I'd love to own (but can't afford). In your experience, are KTM adventure bikes reliable for a RTW trip?

Did you say 'Mineral Oil'? Don't go to Port Augusta for it then..lol Nice one Mr Clutch King.

Great vid. Where did you buy the new seal? Ktm dealers say they don’t list it and have to buy a whole new slave cylinder !

Nothing's like a "how to do it" video to take your mind off things.

pretty simple setup.

Thank you for the video mate.showing where everything goes. I wanted to ask whether you knew where I could get that Rubber ring for the piston from as mine is damaged? thank you

Just out of interest: why is the spring on that side? Isn"t it always pushing on the rod this way? In my mind, it should be on the other side to push the piston back to its original place.

My exc 400 clutch dont gain pressure when i pull the lever, the cap is filled and no bubbles. The clutch dont work, what could be?

Can you start it without the clutch slave

Hi! Is that an upgraded clutch lever?

did you ever find a re build kit? i cant find one.

Paper towel?! How could you!

Don't use paper towels! Had to say it, best of luck stuff like that I just pay the dealership to fix. I'm not willing to take it apart to that level