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MAINTENANCE WORK ON CHASSIS AND ENGINE
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ENGLISH
45
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, fill up with brake fluid DOT 4 or DOT 5.1 (e.g. Motorex Brake
Fluid DOT 5.1).
– Never use DOT 5 brake fluid! It is based on silicone oil and of a purple
color. Seals and brake hoses must be especially adapted to it.
– Store brake fluid out of reach of children.
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If
you get brake fluid in your eyes, rinse with plenty of water and consult a
doctor.
– Don’t let brake fluid get in contact with paint, it is an effective paint remo-
ver.
– Use only clean brake fluid taken from a tightly sealed container.
Bleeding of the hydraulic clutch *
If the clutch lever starts to feel unresponsive, the clutch control system needs
to be bled. You will need a bleeder syringe (special tool), available from your
KTM dealer.
Turn the handlebar until the master cylinder is in a horizontal position, remove
the screws [2], the cover [3] and the rubber boot [4].
Fill the bleeder syringe [5] with brake fluid DOT 4 or DOT 5.1 (e.g. Motorex
Brake Fluid DOT 5.1).
– Never use DOT 5 brake fluid! It is based on silicone oil and of a purple
color. Seals and brake hoses must be especially adapted to it.
– Store brake fluid out of reach of children.
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If
you get brake fluid in your eyes, rinse with plenty of water and consult a
doctor.
– Don’t let brake fluid get in contact with paint, it is an effective paint remo-
ver.
– Use only clean brake fluid taken from a tightly sealed container.
Remove the bleeder screw [6] from the slave cylinder and mount the bleeder
syringe. Press oil into the system until the oil runs out of the hole [7] in the
master cylinder without bubbles. Occasionally extract the oil from the mas-
ter cylinder reservoir to keep it from overflowing.
After you finish bleeding, remove the bleeder syringe, mount the bleeder screw,
correct the oil level in the reservoir and mount the cover (see above).
2
4
3
6
5
7
1
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.