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i have figured it out.  mostly.


popped the roll pin outta the clutch arm assembly,  and could not get shift barrel out.  when i finally got it out, i found someone had used a piece of shim stock in there to take slop out of the barrel... so it appears to me that it was binding when under load, and moving around and blocking the pushrod..  so i grabbed one from a 75 motor i had here, and better, but still nowhere near perfect.  going to swap levers around till i find one with some real leverage.

do you measure the clutch arm disengagement point to the boss on the case around the cable hole, or to the case directly next to tthe raised boss?  there's a few mm difference between the two..

i can only assume the first link you sent is the 77 or otherwise basket.   every other example i see is the steel basket with no holes, as  mine is,  and they all show the plates stacked like mine is.  as does the still keeping track article.  i will tear into again now and see what i can find.

thanks for the info - your data should help me get it figured out - i appreciate it.  your numbers show a stack height of 28.25mm

but i have a question  - at http://www.pentonusa.org/publications/newsletters/SKT4.pdf

on page 10 and 11,  it has all different data for later clutches..
3.5mm thick fibers, 1.6x38.5 springs, and shows my plate order (on pg 11 sidebar) for mc 1978 250?  conveniently that article mentions 77 and before and 79 and after. no mention of 78...

also my clutch has the directional fiber plates...


motor date code is 12 of 77..

in that ebay auction it shows a thrust washer - i don't recall seeing one on my clutch - is that between hub and basket or between basket and case trans bearing?


my clutch looks like the one listed here - not like the one you listed.. a totally different steel basket - 6 plates with 2 steels  -

http://www.ebay.com/itm/1978-KTM-MC5-250-Layshaft-Lay-Shaft-Clutch-Shift-Forks-Etc-Parts-Lot-/361327609160?hash=item5420cdc548:g:fEQAAOSwv0tVfyTW&vxp=mtr


or this one here..

http://www.ebay.com/itm/Vintage-AHRMA-MX-1976-1978-KTM-250-MC5-Clutch-Basket-Assembly-/201375274948?hash=item2ee2e6d7c4:g:GskAAOSwNSxU8zc6&vxp=mtr

can anyone tell me proper stack order, and maybe the stack height?

mine is set up 2 steels, then 6 friction/steels.  S-S-f-S-f-S-f-S-f-S-f-S-f-S-Plate

clutch won't disengage and clutch action is EXTREMELY hard to pull.  

i set springs even and runout is good - i set springs with just barely enough to get the wire through...

clutch actuator arm moves smoothly with no side play/slop.

cable is new, magura lever, and temp routed totally loose.

any help is appreciated - thanks!