Using a newer inner hub and clutch basket to repair older style 1994-2003 KTM 250/300/380 EXC MXC models
Note, the inner hub should fit all the way back to ‘94. I have confirmed it on 1998 to 2000 models.
I have added a list to the end of this document that lists the model that this hub was used on.
Clutch Basket, Outer
The clutch basket is pretty easy, the newer models will just bolt on, however, the inner hub is slightly different.
The original clutch basket PNs are:
54632001272 OUTER CLUTCH HUB 72T PRIM. 25T
54632001372 OUTER CLUTCH HUB 72T PRIM. 26T
They are still available but pretty expensive, probably due to the fact that the primary gear is included.
The basket alone is PN:
54632001200 Outer Clutch Hub Loose
At the time of this writing, it was no longer available, it also requires rivets to install.
Aftermarket clutch baskets designed for 2008 to 2012 bikes will fit using their designed mounting bolts.
Clutch baskets that have been confirmed to fit:
ProX 17.6323F
Hinson H200
Wiseco
Barnett 321-48-01005
Inner Clutch Hub
The original clutch hub PN:
54632002200 INNER CLUTCH HUB
Is no longer available.
You can use a newer model:
54832002000 Inner Clutch Hub 546/548 2003
With 2 of these washers:
57532013000 Supportwasher 22,2X35x3 Harde
Note: Stock there is 1 washer behind the hub, you only need to order 1.
The newer hub works perfect in the older bikes, however you need one more washer behind it.
The newer hub is exactly the same except they have milled 3mm more off of the center where it is
bolted to the shaft. We had one of ours apart replacing a shift star, and I have a new hub in stock so
I took these pictures.
Old hub vs new hub
Depth measurements where shaft goes through splines. Old vs new.
Old vs new with extra washer, side view
Clutch basket, outer, with 2 washers, ready for inner hub install
After install, outer basket and inner hub tops should be even.
Installed in the above pics
17.6323F Pro-X Billet Aluminum Clutch Basket
57532013000 Supportwasher 22,2X35x3 Harde <---- 2 of these washers
54832002000 Inner Clutch Hub 546/548 2003
A few things to add to the project
Check the bolt that secures the shift drum, this is notorious for working loose.
Do not attempt to remove the clutch assembly without a good clutch basket wrench.
I recommend an EBC Clutch Tool #CT007 KTM
Always replace the lock washer
56532018000 LOCK WASHER
Damping Elements
Some of the aftermarket clutch baskets do not ship with the rubber Damping Elements. They are still available:
58132026000 DAMPING ELEMENT
You will need 8 of these, if there is any slack in yours, or they are the original, you should replace them.
Clutch Kit
If you look at the parts diagrams starting in '08, they list a clutch kit that is cheaper than buying the fibers,
steel plates, and springs separate.
Clutch Kit 250/300 '04-'12
54832011010
Plastic Shift Locator
While you are servicing the clutch, if your model still has the plastic shift locator, I highly recommend
replacing it with the newer all metal model. On older bikes these fail and make you believe your
whole gearbox is trash. Usually the symptoms are crappy shifting, or stuck in a gear.
The newer models are:
59034015144 SHIFT LOC'ING DRUM ALU CPL.00
59034015044 Shift Drum locating complete (This is all alum, but not available any longer)
Note the above all metal assembly replaces 2 parts on from the older models:
54634013044 DRIVER F.SHIFT ROLLER W.NEEDLE
54634015000 LOCKING ROLLER
Old model Inner Clutch Hub
https://www.ktmworld.com/oemparts/partsearch/ktm?partsearch=54632002200
Assemblies where 54632002200 is used
1994 250 EGS - Clutch
1994 250 EXC - Clutch
1994 250 SX - Clutch
1994 300 EGS - Clutch
1994 300 EXC - Clutch
1994 300 MXC - Clutch
1994 300 SX - Clutch
1995 250 EGS - Clutch
1995 250 EXC - Clutch
1995 250 SX - Clutch
1995 300 EGS - Clutch
1995 300 EXC - Clutch
1995 300 MXC - Clutch
1995 300 SX - Clutch
1996 250 EGS - Clutch
1996 250 EXC - Clutch
1996 250 SX - Clutch
1996 300 EGS - Clutch
1996 300 EXC - Clutch
1996 300 MXC - Clutch
1996 360 EGS - Clutch
1996 360 EXC - Clutch
1996 360 MXC - Clutch
1996 360 SX - Clutch
1997 250 EGS - Clutch
1997 250 EXC - Clutch
1997 250 SX - Clutch
1997 300 EGS - Clutch
1997 300 EXC - Clutch
1997 300 MXC - Clutch
1997 360 EGS - Clutch
1997 360 EXC - Clutch
1997 360 MXC - Clutch
1997 360 SX - Clutch
1998 250 - Clutch
1998 300 - Clutch
1998 380 - Clutch
1999 250 - Clutch
1999 250 SXS - Clutch
1999 300 - Clutch
1999 380 - Clutch
1999 380 SXS - Clutch
2000 250 EXC - Clutch
2000 250 MXC - Clutch
2000 250 SX - Clutch
2000 250 SXS - Clutch
2000 300 EXC - Clutch
2000 300 MXC - Clutch
2000 300 SX - Clutch
2000 380 EXC - Clutch
2000 380 MXC - Clutch
2000 380 SX - Clutch
2001 250 EXC - Clutch
2001 250 MXC - Clutch
2001 250 SX - Clutch
2001 300 EXC - Clutch
2001 300 MXC - Clutch
2001 300 SX - Clutch
2001 380 EXC - Clutch
2001 380 MXC - Clutch
2001 380 SX - Clutch
2002 250 EXC - Clutch
2002 250 MXC - Clutch
2002 250 SX - Clutch
2002 300 EXC - Clutch
2002 300 MXC - Clutch
2002 300 SX - Clutch
2002 380 EXC - Clutch
2002 380 MXC - Clutch
2002 380 SX - Clutch
2003 250 EXE - Clutch
2003 250 MXC - Clutch
2003 300 EXE - Clutch
2003 300 MXC - Clutch