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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 RUN-
NING. DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY
COOLED DOWN, TO AVOID BURNS.
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 clockwise reduces the distance between the
clutch lever and the handlebar. Turning the adjusting screw counterclockwise
increases the distance between the clutch lever and the handlebar.
ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER-
TAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY
EXCESSIVE FORCE.
MAINTENANCE WORK ON CHASSIS AND ENGINE »
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 biodegradable SAE 10 hydraulic oil (Motorex Kupplungsfluid
75) to the 125/200 models and DOT 5.1 (Motorex Brake Fluid 5.1) brake
fluid to the 250/300 models, available from your authorized KTM workshop.
– KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE
HYDRAULIC CLUTCH IN 125/200 MODELS. DO NOT MIX THIS OIL WITH ANY
OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAI-
LABLE FROM YOUR AUTHORIZED KTM WORKSHOP) TO MAKE SURE YOUR
CLUTCH OPERATES SMOOTHLY. NEVER REFILL WITH BRAKE FLUID.
– BREMBO CLUTCH FITTINGS ARE INSTALLED IN THE 250/300 MODELS AND
FILLED WITH DOT 5.1 BRAKE FLUID. TO MAKE SURE THE CLUTCH OPERATES
SMOOTHLY, NEVER ADD HYDRAULIC OIL TO THESE SYSTEMS (A SUITABLE FLUID
IS AVAILABLE FROM YOUR AUTHORIZED KTM WORKSHOP).
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