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My sons 2015 KTM Clutch problems

When he shifts bike into gear the bike stalls. When the bike is in gear pulling in the clutch does nothing.How do I fix this?

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  • Master
  • 813 Answers

Hi,again so its not hidrolic clutch its a cable so this should be easyer to sort out just follow the advice I gave in your first question.
good luck

Posted on Apr 18, 2015

  • Jason Kemp
    Jason Kemp Apr 20, 2015

    It is a hydraulic clutch. I had it working, then at the race Sat. it went out again. This time it was out of hydraulic fluid and the rubber gasket that goes insideof theresevoir has swelled up so big it wont fit back inside the resevoir. Have you ever heard of that happening?

  • Paula Hamilton Apr 20, 2015

    I had a gs850g and that had the same problem,I dont know if its a rare thing to happen,I just got a second hand reservare from the scrapyard,thanks for letting me know.

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Posted on Jan 02, 2017

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1 Answer

Have a 2007 ktm 525. Having the same clutch problems not disengaging. Now it's stuck in 5th gear. Can anyone offer any help as to what the problem may b


That is an annoying problem, huh? Have you properly adjusted the clutch freeplay both at the handlebars and at the clutch arm? If you are still having trouble getting the clutch to let go, you might consider checking to see if the clutch springs are shot, but I doubt this on such a new bike. In fact I'm curious if you have a cable clutch at all, or if you have a special hydraulic setup. Anyway, once you get the clutch operating you can get out of 5th gear by pulling the clutch and rocking the bike back and forth while shifting down. Do this with the engine off.

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1984yamaha virago 1000. with the bike running, when I try to shift from neutral to first gear the bike stalls. I think it has something to do with the electrical.. Help!


If you are at idle, in neutral, with the clutch lever pulled all the way in, and you shift into gear and the engine dies, it is likely the switch at the clutch lever. When they fail the bike does not get the signal that the clutch is disengaged and it is safe to shift into gear. Have that switch checked. Some bikes also have a side stand switch, make sure your side stand is always up before putting you bike into gear.

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Clutch does not engage well, especially when cold. First shift into gear will always stall motor.


to me this seems a case of many things not 100% set up properly.

big singles do burn a lot of oil, so either its low or just the wrong viscosity, check with a KTM forum as a lot of users will have already had this problem and rectified it.


but the first thing i'd check first is: Idle speed (if its FI then shouldnt be a problem) valve clearances and it also depends on whether you have any mods?



a race spec pipe will always cause issues starting cold.

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I have a 2003 ktm 250sx and when shifting at high rpm's it won't shift.


How is your clutch? Does it slip or drag when starting out? When you put it into 1st gear when starting out does the bike lunge forward? Hold it in first gear with the clutch in and rev the bike up. See if the bike wants to move forward with the clutch in.It sounds to me like your clutch isn't set right or getting worn out. Much easier to shift at low rpms on a clutch than high rpms. I hope this helps...

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Start bike in nutral hold in clutch put into first and imediately stalls


G'Day mate,
Sounds like the bike has a stuck clutch, where the pressure plates and clutch plates are not disengaging, probably from sitting for a while. Check the clutch adjustments first to see that you have good operation and tension in the clutch lever. To break it free, try first allowing the engine to heat up to operating temp, this can sometimes allow the clutch to free up with heat expansion.
If you can get the bike to a rolling start(mate pushing) and get into a gear, go roll on and off the throttle a few times with the clutch pulled in, see if you can break it loose. Some peps have success with wrapping wire about the handle bar holding the lever in, and let it sit over night, let the oil into the clutch plates.
Dont get too carried away with dropping it into gear with the engine running. You dont want to do more damage. If it remains an issue, you will have to remove the clutch cover and tear the clutch down. check plates for wear and warping. Replace if required. Good luck with it.
regards robotek

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Hi, Mark for this scenario you will need your service, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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http://www.partsfish.com/page/oem-parts-for-ktm
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it may just be the fibers sticking. If the bike has been sitting for a while the fibers will dry out and stick. I would remove all of them, and while keeping them in order dip them into some clean oil and replace them one by one. Be sure to inspect all of them for damage or excessive ware. Good luck.

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