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No I actually believe it is a ktm directive. It used to be US companies just refused to believe that there was an outside world and wouldn't ship. Problem solved itself. They came back and said no stock. Sigh.

I believe it's the smaller gear (behind the primary gear), which meshes with the kickstart idler gear, that backs out. Mitani has a writeup about it here: http://mitani-ms.jp/info/2013/09/rtl-f-clatch-outer/ It's in Japanese, but my browser did a good enough job of translation to get the idea. Mitani makes an improved part, but it's not clear how they improve it: https://mitani-kobe.shop-pro.jp/?pid=60396201

new original piston ! 88.9kg with half tank ... I think 91 kg with a full one and the iron side stand.

@F5Dave "They weren't allowed " what is that so outsiders cannot notice that the rising price of fuel is affecting the cost of shipping adversely. Strange days. Have fun. Regards Alan

Cheers After mucho time searching. . . OK so I've ordered what I believe is the 1.2mm spring with PN MT22020GG-CGI-1 from KTM World in the US. They weren't 'allowed' to ship internationally but I'm using NZ post shipping service. So far i'm in $25 US to get it delivered inter US. - about $50 NZ. Then the same to get it to NZ. Unless they pack it in a helmet box the way the US shops seem to so it doesn't get lost by US Post. By which time it will cost the same as the GDP of Equatorial Ghana. I'll wait till it actually gets here (about when the Sun runs out) and measures 1.2mm before I buy the other parts. In the meantime I'll count to three as I let the clutch out, and by the time I get a kit together I wont need it

@F5Dave Hello , Looks like you are getting somewhere with this now , The reason I suggested the 2007 onwards is because it will be the most likely available as a scrapped bike that will have a 1.5mm thick Belville spring , bearing in mind that this if original has been under pressure for a long time also it will have been used quite a bit and so will be weakened , therefore more like a 1.2mm thick spring . Finding earlier GasGas Pro bikes scrapped is quite easy but the later model PROS' are not being scrapped yet in numbers that make parts cheap. It just widens your search and makes it cheaper by starting with a 2007. If you can find a breaker with a post 2015 that's within budget then you will have what you perhaps require , But bear in mind the TRIALWORLD.ES kit supplies the spring that you already have in your bike as part of their version of the soft clutch kit. . Good luck with your search . I hope it works out and you get the clutch effect you want. Best wishes Alan.

From Hell site Clutch Belleville Spring 2015+ 1.2mm This is the lightest of all the Belville springs used on the GasGas TXT diaphragm clutches. Early ones were 1.7mm, (2002 - 2005) then they reduced the thickness to 1.5mm (2006 - 2015), and post 2015 were down to 1.2mm (except GG CONTACT)

Thanks so much for posting. Looking at the parts diagram for my 2023 One RR it already has PART # 05011MT100. So I think I'm back to try find a GG 1.2mm spring, that seems to be the hard part to track. I've been onto the local guy here for old stock but he can't help. My CGPT searches have not dug anything up. I've tried ebay but will now extend to try find a 2nd hand clutch. Why do you say 2007? From that year only, or likely several do you think. I'll try scope parts diagrams. My 2014 TX had a MT280632015. Hmm, searching says it is a 1.5mm, grr.

@F5Dave The parts in the TRIALWORLD.ES WEB SHOP SITE show that the spring for their soft clutch set up kit is PART # 05011MT100. This spring is the same one used as standard fitment in the 2018 125/250/280/300cc bikes if this is the case then making the Clutch pack 10.00mm thick and adding the "Hard" adjustable clutch support ring is all that is needed to improve the clutch. Check it for your self in the relative info I put on from Trialworld.es and Non-Stop. All the parts you need are all available as supplied from the TRS parts catalogue.

@ F5Dave Here are the measurements used by TRS to make the clutches suit three types of rider: Clutch pack thickness. Held in hand Spring thickness Adjustable clutch ring support EXPERT 9.85mm 1.5-1.7mm DURO/HARD INTER 9.85mm 1.5mm MEDIO/MEDIUM NOVICE 10.00mm unknown DURO/HARD The unknown spring is probably going to be around 1.2mm thick . If a GasGas Pro spring will fit then get a second hand clutch out of a 2007 on GasGas Pro and use that spring and see how that works along with a hard clutch support ring and a 1.6mm clutch steel plate or whatever you need to do to get the clutch pack thickness to 10.00mm.

I had it apart again today and it had pushed itself out again. I have heard of people machining a grub screw in to hold it but I’m not brave enough to attempt that!

That’s the one, just pressed in. No rivets.

Do you mean large gear that engages with the primary drive? Isn’t that pressed into the aluminium basket with rivets?

I got a quick reply from Hellteam and he explained that thier issue was getting bits out of GasGas ktm. I don't mind paying a bit of r&d if it saves me buying parts then getting slip, more parts more freight more spoiled rides. . Hey thanks so much for that info. I'll go searching, maybe AI can find areas of Web I don't for S3 kit. Funny I bought some different plates for my TXT250 when I was buying mc seal kit but never used them. All went with bike but bet 1.6mm plate was there knowing my luck. The GG clutch was just what I'm looking for in action.

Almost positive your ignition components are made by Leonelli and used on several other makes and models of motorcycles, black box with 4 wires would likely be a Bridge Rectifier that converts AC to DC unregulated, the 3 legged IC sounds like a Thyristor which is a rectifier/relay that acts as a voltage regulator. 2 orange wires from stator would likely be your non-regulated AC power outputs, round thing with 2 wire connections is likely the temperature thermostat seeing as it must have one somewhere. Search "Leonelli Thyristor" and "Leonelli Fan Regulator" and see if those parts look recognizable.

Where in the country or world are you? Plenty of people take on project bikes for the challenge of getting them running again. Do let us know.

If you see a set of cases apart there is only one correct position as the case has a relief to keep it in the correct spot. I have added an image below for reference. So place the kick start stop in and rotate until you feel it is in that captured relief, then screw it down.

Many thanks for all the responses. I did end up having the clutch basket off, the gear on the back of the basket had pushed out slightly. After pressing back in and using some loctite it seemed to have worked but after a hard trial the issues came back… Will look into changing out the Elf and having it all back apart! Many thanks

https://int.nonstopbikes.com/blog/trrs-clutch-upgrade-kit-2018-current-5c/ As it is a S3 kit then a trials shop some where in the world probably has 1 in stock .as of yet unsold but if you do not search you will not find it's that simple. I will have a guess that the reason they do not have the video on the site is probably because people could then work out that they could make up a kit themselves from individual parts and do it cheaper using Casales' tips on how to fit the bits to achieve a soft clutch.

The kit is made by S3 parts in Spain it has 1x clutch steel plate 1.6 mm thick , 1x diaphragm spring and a adjustable spring support ring (duro) which means hard in english . www.trialworld.es has them listed at 99 Euros as a TRRS CLUTCH IMPROVEMENT AND SMOOTHING KIT. S3 is a company that for decades has made all the motor cylinders for nearly every Trials bike made in recent history. Try e-mailing S3 parts and see what they say.

Hi I am looking for some help with the electrics on this machine which I purchased as a pile of parts. The machine is a 2001 model I am looking for some guidance on the electric fan circuit and cant find any drawiings on this, no wiring was with the machine. I have what appears to be a small black box with 4 wires and a small 3 legged IC, which i assume that this could be the ac dc converter and possibly a voltage regulator and would appreciate some help on how to wire these components, The Stator has 3 wires one black and 2 orange There is also a small blue 2 terminal round box fixed to the fan cowling, can anyone identify this unit Regards Dave G

Yes, on both counts. (I would not have survived this repair w/o Jim.) In fact I let them sit bathing in oil for a few days on the bench while I pondered the situation and researched the topic. It seems that, like Nigel & I have found, that these brngs are REALLY tight right out of the box so I'm proceeding w/ the reassy w/ skepticism but it does seem like the more I move them the better they feel. Was just hoping that Nigel would reply back w/ positive vibes to keep me motivated. Edit: Oh wait, I am using the old style brngs, not the low friction versions. (I did not know the diff when I ordered)

Yeah - that's the one, but the best shot in the video was w/ the cases split, and I was having trouble believing that it should be free standing and not up against the other case half for support. Well, I tried the position that I felt would be supported (max clockwise) but then it rubbed against the K/S shaft bushing, so I rotated it back, even more CCW beyond the photo and all seems to work well now, so there I have it - Jim (and you) are right! Now I'm a believer! 😉

Yes but they have done the research on what works. Its not a TRS kit from what it says. I've emailed them to see if they have the other two parts, spring and friction.