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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Changing the original position of the clutch lever
The adjusting screw [1] 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.
Turning the adjusting screw counterclockwise reduces the distance between
the clutch lever and the handlebar. Turning the adjusting screw clockwise
increases the distance between the clutch lever and the handlebar.
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
To check the oil level in the master cylinder of the clutch remove the cover.
For this purpose, remove screws [2] and cover [3] together with the rubber
boot [4]. 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 workshop.
KTM uses biodegradable hydraulic oil for the hydraulic clutch
control. Never mix biodegradable hydraulic oils with mineral oils. Never refill
with mineral hydraulic oil or brake fluid.
Bleeding of the hydraulic clutch
To bleed, the cover of the master cylinder of the clutch needs to be
removed. For this purpose, remove screws [2] and take off the cover [3]
together with the rubber bellows [4]. At the slave cylinder of the clutch, remove
the bleeder nipple [5]. In its place, mount the bleeder syringe [6] which is
filled with SAE 10 hydraulic oil. Refill oil, until oil is discharged from the
bore [7] of the master cylinder in a bubble-free state. Make sure that the oil
does not overflow. The bleeder syringe can be purchased from your KTM
dealer.Having completed the bleeding procedure, you have to verify that the
oil level in the master cylinder is correct.If necessary, fill up with
biodegradable hydraulic oil SAE 10 (e.g. Motorex Clutchfluid 75).
Biodegradable hydraulic oil is available from your KTM dealer (50ml).
KTM uses biodegradable hydraulic oil for the hydraulic clutch control. Never
mix biodegradable hydraulic oils with mineral oils.
Always use biodegradable hydraulic oil SAE 10 (e.g. Motorex Clutchfluid 75) to
fill up the master cylinder. Never refill with mineral hydraulic oil or brake fluid.
3-5 mm
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Adjusting the throttle cable*
There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To
check this, move back the protective cover [8] on the throttle grip. You must
be able to lift the outer covering of the cable 3-5 mm from the adjusting screw
[9] until resistance is felt.
To adjust, loosen the counternut [10] and turn the adjusting screw accord-
ingly. Finally tighten the counternut and slide the protective cover back on.
To check the correctness of this setting, start the engine, turn the
handlebar left and right, in both cases as far as it will go. This must not cause
any changes in idling speed. Otherwise, you will have to increase the
backlash of the throttle cable.
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