Reply from DJH
Don't ask me what he means, but hre is a reply from DJH (David):
"Standard problem on bike of that era, history;
2000 model had a clutch that spun on a bronze bushing (needed lots of oil) so the routed oil pressure passage into the cavity between the slave and the left side mainshaft bearing so oil would flow thru the main shaft and into the clutch. The oil pressure build up at revs simply pushed the slave cylinder back in so all the fluid in the system flows backwards to the master cylinder, then when you pull the clutch the lever is floppy.
2001 they changed the clutch to a needle bearing which does not need the oil but did they change the oil system, uh not until 2003. Welcome to how KTM deals with problems.
Good news is we have a fix, un-bolt the slave and set it aside, looking in you will see an orange plastic ring, that is the seal of a sealed one side bearing. All we need to do, I use a ice pic, just peal back an edge of that seal, go in with needle nose pliers and rip it out. Now the oil flows into the trans, no pressure build up, clutch works like its supposed to. Done many of 'em"
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2011 Husaberg TE 300
2002 640 LC4e 
Past Rides
'03 KTM 450 EXC (SOLD)
'01 Honda XR650R (SOLD)
'98 Honda XR600R (SOLD)
'95 KTM 620 RXC (SOLD)
'88 Yamaha TT600 (SOLD)
'86 Yamaha XT 350 (SOLD)
'84 Yamaha IT465 (STOLEN)
'83 Kawasaki KDX 450 (SOLD)
'83 Honda CB1000 Custom (SOLD)
'82 Kawasaki KDX 400 (SOLD)
'77 Yamaha DT200 (SOLD)
'70 Honda CT70 (SOLD)
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the clutch has gone completely soft nothing there at all??? shocked at this we bleed the system again and again every way possible to make sure no sneaky bubbles were in our way. again on start up the clutch goes soft! the master cylinder is under 12months old the slave cylinder has just been replaced and working fine the whole system has no leaks or deffects anywhere and feels great ready to ride untill you turn the bike on. after stuffing around with the clutch side of things for days trying every little thing could find on the net remotely close to this problem including checking crank exhaust emissions an't blocked. oil lines and holes still flowing and an't obstructed. well all the ones we could test and try anyways. clutch disk not warpped or bent. and just this arvo we found with the clutch case still off if someone pulls the clutch in and another puts pressure on the pressure piece connected to the push rod the clutch goes soft? depending on how much you push on it depends on how quick it goes soft. and then you just pump the clutch and it starts to come back again. so when the engine is on the engine pressure is pushing on the piece and giving you the soft clutch? the clutch plates move normally along with the pressure plate everything seems normal except around the rod, pressure piece bolt thing and the pressure plate bearing. when we first opened it up the pressure piece was stuck that firm in the pressure plate and bearing we had to use alot of effort to free it up and pop it out? now how tight does the pressure piece have to be inside that bearing as it still has to be able to move but not get stuck? so we shimmed it a bit to a snug fit but so it still could move. but still the same problem continues???? any advice or help would be appreciated guys
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