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Did not see your earlier post saying you pressed it on using some loctite. As that is the case you know what your options are so its a closed case. I am talking to myself of course.

I know who you are and that you are a serious rider on Honda machinery and therefore know what you are talking about but Mitani who have pretty good knowledge of the Honda motors engineering wise reckon this movement can happen in approx 1 year of use. With the amount of torque the motor produces and the abrupt use of clutches in trials sections ,as happens, then an interference fit steel part in a softer aluminium outer part is going to start twisting and enlarging the alloy part in the same way that the rivet holes on the clutch bell elongate in the end and give rise to slop. I am happy to go with Mitanis' view based on engineering.

Shouldn’t have come apart like that. A new one won’t be cheap but a 2nd hand one may be worth a try. I would think Richard Allen trials spares would have some. If you’re really stuck I have one on a spare engine.

I think the rules in the UK are very clear. The rule is NO STOP with stop allowed. Watch this years SSDT , a trial that is marked under the no stop allowed rule , and the top riders were stopping and then hopping the back wheel sideways about a foot before setting off again at certain sections .That in my opinion is not stopping , stopping is when you have not moved for more than about 5 minutes which is still not really stopping it is a brief lull. I hope that clarifies the current system. If stopping was stopping Doug Lampkin would have had quite a few more marks than he did along with plenty more of the field of riders. Rolling backwards is OK as long as the observer on duty thinks that it is. Remember , as long as the observer follows his own set of rules and applies them exactly the same to all participants , then it does not really matter what the actual rules are.

I can see the arguments for both no-stop and stop allowed. I'm inclined to the idea that stop allowed is necessary at national and international level but not a good idea for club riding. Both systems leave a lot of grey areas that really need to be clarified by the rules. It would really help if the ACU and AMCA (in the UK) would publish rigorous rules about stopping so that riders are no longer marked at the whim of the observer.

Perhaps something like LOCTITE 270 anaerobic permanent adhesive could help or a strong bearing retaining anaerobic adhesive. such as LOCTITE 638

@Guidoxpress Looks like a one -off home made job. You can extract the (screw threaded part ?) that is still in the post of the clutch casing and take both parts to a machine shop and get them to make a replica of the broken part or get a new or second hand casing .

we have a broken clutch piston, assuming that’s what this piece is called. Can’t find it anywhere and can’t find it on any parts breakdowns : any help?

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.