TE/TC TE250 Clutch issue

So I just picked up my brand new 2014 TE250 and took it for a quick spin. Great bike except the clutch fully disengages so close to the bar you can't have any fingers on the bar. The bike still drags itself forward with the lever pulled to my fingers and if you don't keep on the gas it stalls. This is a serious problem for any technical riding.I've adjusted the lever so its all the way out but there is no change. The clutch does fully engage in the normal spot farther out but there is an absurd amount of drag through 90% of the lever range. Could this be due to air in the Hydraulic system? The bike is currently unridable in a race situation.

I just got my te 250 this month as well. I had the exact same experience where the clutch feels very tight and always wants to go. As soon as its in gear its pulling ahead with the clutch lever pulled in and unless the idle screw was turned up it would stall out while stopped in gear (clutch lever in). However I've got 3 hours on it now and it seems to have improved a little which has me thinking that maybe it just needs to break in a bit, maybe wear the clutch plates down slightly. This is my first new bike so I'm getting used to the break in process but seeing as you have the same issue it may just be that.

Well at least we aren't alone. I have 2 hours of mx track use on my bike with heavy clutch abuse (old school track with next to no jumps, these bikes are definitely not suited for jumps) and its mildly better. It seems to vary significantly while riding, sometimes okay and sometimes grabby. I'm really hoping it continues to improve, as me buddies have KTMs and they are nothing like this. I'm also finding the clutch pull terribly heavy with a terribly long clutch engagement in comparison to my previous cable clutch equipped Honda.

Other than the clutch the bike is pretty slick. I still would prefer less of wide ratio transmission so that there would be less clutch use to keep it in the power. The suspension/chassis is to die for, tracks smooth and straight through the roughest of terrain and braking bumps, no harsh mid stroke on the 4CS forks as some people complain about. I'm also 20lbs more gear'ed up than the spec'd weight for the stock springs so I can only imagine it gets better when properly sprung. Also the electric start that is on it is flawless.

KTM talk thread for '12 6 spring clutch, as opposed to '14 DDS clutch, but should apply. I have a '12 Husaberg TE250, with a Rekluse EXP and adjustable slave cylinder. I can adjust clutch lever engagement on slave cylinder.

http://ktmtalk.com/showthread.php?t=479855&highlight=Clutch Adjustment&page=2

Well I ordered a new Belleville spring from KTM today in hope that its merely a non uniform spring pressure issue. The pressure plate does in fact not lift evenly and is engaged on one side with the lever pulled in. The springs are dirt cheap so here is to hoping for a simple cost effective solution.

Not sure this applies to your issue.... Another spring option, but not dirt cheap. I know some racers using this, as they felt the stock spring made the clutch too smooth.
http://slavensracing.com/shop/280-p...er-for-ktm-husaberg-250-501by-ktm-powerparts/

sthomps, have you tried the new Belleville spring yet? I rode my TE250 around the parking lot at the dealer the other day and was surprised by how much the clutch dragged. I ride trials as well, where the clutch is everything, and that much drag is unacceptable.

[uote="DualSpaz, post: 412268, member: 2181"]sthomps, have you tried the new Belleville spring yet? I rode my TE250 around the parking lot at the dealer the other day and was surprised by how much the clutch dragged. I ride trials as well, where the clutch is everything, and that much drag is unacceptable.[/quote]

I have not had a chance to install the new spring. Still up at site. I'll have it installed and tested this Friday and will report back. I totally agree though, its unacceptable and for any of the technical stuff and enduro cross sections that are on courses it's a major detriment. I

Probably just a limited batch of bad springs - my TE clutch works perfectly. The clutch pull is very light, no drag, and engages/disengages without a hitch no matter how I adjust the clutch lever.

Same with my TE300 no clutch issues, in fact it is the best clutch I have ever used.

Any update on this?

Barnett has a 20% stiffer spring available now, listed under KTM....
http://www.barnettclutches.com/2020/ktm/0/0/2014-ktm-250-sx-xc-xc-w.html

wow ... I guess it's safe to say a can-opener is a can-opener, no matter how it is branded or its price ...

Good luck with your bikes.

OK so I just installed the new spring and played with the retainer ring indexing and so far so good. No more drag and the clutch action is exactly where it should be. I'll let you know after a full ride tomorrow.

So my clutch is awesome now. Works perfectly and can adjust the lever to anywhere I like. Now its time to see if the dealer will pay for the clutch spring.

So what spring did you end up getting? The 280psi from slavens? And what did you adjust the retainer ring to? X? Z? I'm glad you got it right. Now I need to do the same. I'm excited just thinking about

Sorry, just realized you ordered the spring from KTM. So was it the same OEM spring or a stiffer one?

I just asked for a 2014 250xc spring. Its not a stiffer spring. Make sure the thing ring under the spring is fitted on the right side up. It is marked "top", and I'm not sure how mine came but maybe it was installed upside down. As for the index ring I recommend playing with the setting. It takes no time at all to spin it off and adjust it. I currently have it set on the thinnest setting which is the supposedly the heaviest pull at the lever but it feels light to me.

Was having the same issue with my TE300, will have to try a new spring to fix the issue. Thanks for all of the information.

How much did your spring cost you? My dealership said they're $36. But that's Canadian eh.

I tried bleeding the clutch again (did get some air out) and even loosened and re-torqued clutch bolts on spring retainer ring but all to no avail. Still drags like crazy. So I ordered a new spring. Hope that cures it