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Changing the original position of the clutch lever
The adjusting screw [4] can be used for individual adjustment of the original
position of the clutch lever, thus allowing adjustment to an optimal position
for every hand size.
The clutch lever moves closer to the handlebar if the adjusting screw is turned
in a counterclockwise direction. The clutch lever moves away from the han-
dlebar if the adjusting screw is turned in a clockwise direction.
Adjustment of the clutch lever position is only possible within certain limits.
Only turn the adjusting screw manually and never apply excessive force.
Checking the oil level of the hydraulic clutch 125/144 SX
To check the oil level in the master cylinder of the clutch remove the cover.
For this purpose, remove screws [5] and cover [6] together with the rubber
boot [7]. The oil level in the horizontal-standing master cylinder should be
4 mm below the upper edge.
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid
75), available from your authorized KTM shop.
KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch
in 125/144 models. Do not mix this oil with any other hydraulic oil. Always
use original KTM hydraulic oil (available from your authorized KTM workshop)
to make sure your clutch operates smoothly. Never refill with brake fluid.
Checking the oil level of the hydraulic clutch 250 SX
To check the oil level in the master cylinder of the clutch remove the cover.
For this purpose, remove screws [8] and cover together with the rubber boot
[9]. The oil level in the horizontal-standing master cylinder should be
4 mm below the upper edge.
If necessary, add DOT 5.1 brake fluid (Motorex Brake Fluid 5.1).
BREMBO clutch fittings are installed in the 250 models and filled with DOT
5.1 brake fluid. To make sure the clutch operates smoothly, never add hydraulic
oil to these systems.
MAINTENANCE WORK ON CHASSIS AND ENGINE »
Exhaust system *
If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn.
Have the filling checked regularly by an authorized KTM workshop (see
Lubrication and Service Chart). The insulating material fibers escape through
the holes in the perforated pipe with time, causing the silencer to “burn out”.
In addition to causing a higher noise-level, it will also affect the power char-
acteristic. The insulating material suitable for your exhaust is available from
your authorized KTM workshop.
To replace the glass-fiber yarn set [2] remove the end cap and pull off the
outer pipe [3]. Tape a new glass-fiber yarn set to the inner tube and slide on
the outer pipe. Mount the end cap.
Make sure the caps are screwed on tightly. Mount the muffler stress-free before
tightening the fixing screws.
The exhaust system becomes very hot while the motorcycle is running. Do not
start work on the exhaust system until it has properly cooled down, to avoid
burns.
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