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  1. OK.........thought I would just update this post given all the the support and advice given. Just back from holiday on Thursday and all parts arrived. Spend way longer yesterday replacing the clutch plates. What should have been a relatively simple task got a bit more complicated when I dislodged one of the clutch fingers when removing the old plates and it fell into the motor behind the clutch basket. This was amazing given the bike was upright on a stand. I could see the finger but with all the will in the world I could not get it out so needed to remove the clutch basket. Simple you say. Well first I did not have a 27mm socket on hand as some of my tools are at another property. Got a socket and undid the nut only to find the basket does not fit through the clutch cover opening. The 2006 has a 2 peice cover and needed to remove the whole engine cover so off comes the brake lever and removal of the engine cover about 1 cm and the finger rolls out. So all good. Put all back together and seems to have resolved my problem. Have only run around the street here for 5 minutes as only have Rec Rego but all seems to be good. Looking at the old clutch plates 2 of the metal plates are very warped and con-caved. Odometer has 11,000 km and was amazed by how good the internals look. Not the original owner so not sure what is original but the bike has been very reliable so far. Thanks all for the great advice and MrNoodles for his template idea which was very handy.
  2. Clutch pack delayed until next week and then away for a bit so won't get to swap this out for a couple of weeks. I had a bit more of a play with the bike and clutch today and some very weird behaviour. I started the bike from cold popped it into gear and all was good as gold. Moved the bike forward 10 meters and pulled clutch in and all good. However while sitting there with the clutch in suddenly the clutch gripped and significant clutch drag. I stopped the bike, pumped the clutch and started again. Same thing happened. All good and then after 10 seconds the clutch suddenly started to drag. I replicated this 3 or 4 times so seems there is a loss of pressure somewhere. So may be a leaking slave cylinder into the gearbox as flagged by Bear MX early in the piece as can not see any leaks at the master. I assume this is simply an o-ring replacement senario. Again thanks everyone for the advice and support. Need to fix this so I can get out riding again.
  3. OK.........while I wait for my new clutch pack to show up I decided to strip down the master cylinder and clean it all out as per Eagles suggestion above. Stripped it all down and cleaned it with carby cleaner before drying out and putting back together. Once reverse bled and pumping the clutch lever to ensure no air in the line it seemed better the first change but then seemed to get worse again. Is better than it was but not like it was. before the Hamburger indecent. Worried there might be a leak somewhere as if pumping the clutch it is better but then seems to get worse again. Have new clutch pack hopefully arriving today and picked up a set of half washers as read that if these get pressed they will cause clutch drag. Hard to believe that a simple washer cut in half would cost $14. Guess I should be happy that I can get parts for a 12 year old bike. will update next week once new clutch and half washer installed. Cheers
  4. Thanks BearMX for the great resources and advice. I have watched a couple of YouTube videos and along with the manuals and parts lists above. Looks fairly straight forward however in the videos it showed a set of rubber dampers inside the clutch pack but the parts list / exploded diagram does not show these for my bike. I therefore assume that these are a more recent addition and not something I need to worry about. Also great advice MrNoodle on the cardboard template as I saw that all the bolts are different lengths on one of the videos. Will let you know how I go next weekend. Cheers
  5. OK........have ordered a new set of plates and will test my mechanical skills replacing as well as looking at master cylinder. If I this does not work then I will hand it over to the professionals. What could possibly go wrong. Thanks for the advice from the forum members.
  6. Cheers. I think I will give that a try on Sunday and see if is the culprit.
  7. Yep. Mine uses mineral oil and I even paid up for the oem motrex stuff to no avail.
  8. Thanks everyone for the quick response. Have replaced clutch oil a couple of times and do not seem to be losing level in the master cylinder but have not riden much since this issue started (just around property with kids) so may not enough to notice the fluid lose if a leak in the slave. Think might just have been the end of service life so will look at this and see how I go. Thanks all.
  9. Dear Forum Members and Tech Gurus. I have a 2006 450 exe-f which I have had for 2 years. All has been fantastic until my last Dirtriderz ride at Mt Dissa. I had a bit off an issue with Hamburgers with the KTM going up and over at some stage. Finally got to the top and the clutch was dragging very significantly and I could not come to a standstill without stalling. Struggled on for a bit before retiring for the day. I assumed it was just some air in the line so bought some OEM hydraulic fluid, drained the system and reverse bled the new oil in. Some improvement with able to hold first with clutch in with a little throttle once the bike is warm. But still nothing like it was. I have rested the bike with the master cylinder raised to bleed out any bubbles. No further improvement. I have bled it again with no further improvement. Now I have an odd behaviour where with the lever adjustment in the clutch really drags. However if I wind it out the clutch will drag, engage a little, then disengage and reengage again when the lever is almost right out. So feels like a two stage clutch where if you start to pull it in the clutch disengages then reengages just before the stop and then disengages but drags significantly. Dont know if the issue was caused by the flipping the bike or slipping the clutch up Hamburgers. Bike has done 180hrs but not sure what the service life was before I bought it. Have not changed oils or anything else so I am stumped. Planning to take it in to be looked at as beyond my knowledge know but wanted to check if anyone had any ideas or advice before I go any further. Many thanks
  10. I have the ogio flight vest and love the way it spreads the weight. Only downsides are it gets a bit hot and you end up carrying a lot just because you can.
  11. Well.........ended up with 5 riders meeting at 8.30 on a very warm and humid day. Maccastrewth was there when I arrived and 5 minutes later Floody and ScoTTy rolled up. Was a little worried about Mess but at 8.45 he rolled in and and was ready in a flash. Not a great omen of the day ahead when I was helping Mess get his bike of the ute and it slipped of the ramps. Handlebars did not touch the ground so was not a fall. Weather said 28 and rain but we went all day without a drop. Headed out on some tighter tracks to warm up and within 10 minutes Mess had a small off and broke his brake lever. Amazingly he road the whole rest of the day with about a 2mm brake lever so stopping was a challenge. Headed around through Anderson Gardens and up Quarry road where we stopped for a bite to eat looking over to the back of Hamburgers. After a quick break headed over to Hamburgers for a play. Mess was straight up without any issue or hesitation. The rest of us had mixed results but all needed a couple of trys to get up with one running out of lungs and headed down and then up the chicken track. I ran out of clutch on Hamburgers and struggled fro the rest of the day as could not come to full stop with out stalling. Then battery went flat due to so many restarts and finally ran out of legs after kick starting. Highlight of the day was a very high 360 flip over a log. Bike went about 2M in the air and did a full flip before landing on front wheel and putting the steering out. Decided definately time to head home after that. Thanks to the guys for a great ride and Mess for showing us how it is done. Heres a few photos. Timing with iPhone not great but the one of Floody over the log has to be the pick of the bunch.
  12. I’ve got a 2006 450exef bash plate if anyone needs one. Lost it on a ride and replaced it with a b&b one only to then find it on a subsequent ride. Cheers.
  13. An old Suzuki road bike with a flames painted on the tank. No idea what model is was but went OK for first bike.