Clutch

[Calum]

@Ricky Don't really know what to suggest then.

Could be worn primary drive bearings and pulling the clutch out exacerbates things.

How many miles has the engine done, and has it ever been rebuilt?

[Ricky]

@Calum it's done 20k not sure when it was rebuilt

[Calum]

@Ricky Well if it's original internals then it could be knocking, which will mean it'll need a rebuild.

if it's been rebuilt then it could be that it hasn't been assembled properly, and the engine hasn't been timed up properly. But the vibration when the engine isn't timed up is really bad!

[Ricky]

@Calum it's not that bad I don't think haha but it only started since i put the new clutch in

[Mightyman]

2 stroke KTMs are renound for an unusual sound if you aren't holding the clutch in but what you are describing seems like more than just this..

[Ricky]

@Mightyman this never use to do till I changed the clutch

[Calum]

@Ricky Probably just paranoai. You definitely got enough oil.in there yeah.

[Darty]

Go back in and check the torque on the nuts, is it noisy? like a continuous ticking sound? Clutch plates are slipping if the revs are dying, Re-adjust the clutch action on the clutch itself.

Mine did this once, but vibration suggests bearing, or loose plates, which seems unlikely.

[Ricky]

@Calum haha something is different and yeah 750ml

[Ricky]

@Darty it's more like a thudding noise than a tapping

[Ricky]

@Darty the inner basket spins when I tighten the springs up I've got them tight

[Ricky]

What's the best way to put the metal plates in sharp side facing the engine or the smothered side I've been told it doesn't matter as long as there all the same way

[Mightyman]

Could be worth posting a video so we can hear the noise. Might be easier than describing it

[Ricky]

@Mightyman good idea haha I'll do it later

[Ricky]

A video as promised please ignore the tapping lol
https://youtu.be/BdgV44NU6D8

[Calum]

So what's the tapping?

The fact the idle goes down with the clutch in doesn't really bother me. I see that a lot, usually the thrust bearings going on the clutch, however we don't have those.

What we do have is a primary drive bearing, which if it's on its way out, will vibrate and probably cause this sort of issue.

With that sort of mileage on a two stroke, and an uncertainty of the engines age, I'd be stripping it down for a rebuild...

I don't think we're going to diagnose it really.

If it isn't what I've been suggesting then I really think it might just be an engine rebuild jobby, or paranoia.

If it was really bad then you would know. Again it all comes back to how much vibration. If it's a lot, then it's for a reason. But two strokes rattle a lot anyway so it's really hard to tell.

[Ricky]

@Calum the vibration isn't that bad it's the clutch problem it nearly dies when it's in gear and I pull the clutch in like when I'm at lights waiting to go

[Mightyman]

From that video alone, I really can't hear anything wrong with it. Definitely could be a case of paranoia like Calum mentioned, just from knowing you've been fiddling around inside the engine. The revs dropping sounds as though it's only happening when you push it down into gear. From my experience this isn't all that uncommon with two strokes. My TDR currently does that and it's not something I'm concerned about. Although I have owned a couple of bikes that would simply cut out if you dropped them into gear without revving them quite a bit. They both had worn clutches though.. If you want serious reassurance, take it to a bike mechanic. Any decent mechanic who's worked with DTs before will be able to tell you if it's okay just by listening/taking a quick look.

[Calum]

@Mightyman Yeah if the dropping when it goes in gear then that's different.

Sounds like the clutch is engaging with the lever pulled in.

You could tell if you put the wheel a paddock stand and do it, if the wheel speeds uo then the clutch is engaging.

[Ricky]

@Calum that's it as soon as I put it in natural it picks back up