Exhaust System; Checking The Oil Level Of The Hydraulic Clutch; Bleeding Of The Hydraulic Clutch - KTM 65 SX 2006 Owner's Manual

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MAINTENANCE WORK ON CHASSIS AND ENGINE

Exhaust system *

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The silencer is filled with glass-fiber yarn for damping. When in use, the glass-
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fiber yarn becomes loose or coked with oil carbon. This can lead to a power
loss and a reduction of the silencer damping. The glass-fiber yarn packing
can be replaced in a few easy steps.
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To replace, remove the silencer from the vehicle and mark the position of the
outer tube [1] to the inner tube [2]. Remove screws [3] and the end cap [4].
Pull of the outer tube and remove the old glass-fiber yarn packing [5] from
the inner tube. Thoroughly clean all parts.
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To assemble, mount a new glass-fiber yarn packing onto the inner tube (see
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illustration) and slide into the outer tube. Mount end cap and fix with
screws [1]. Before tightening the screws, turn the outer tube until they match
the positions you marked. Mount the silencer and check the exhaust system
for tightness.
NOTE: Glass fiber yarn packages are offered by your licensed KTM dealer.
THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN-
NING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL
IT HAS PROPERLY COOLED DOWN.
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Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the cover.
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For this purpose, remove screws [6] and cover [7] together with the rubber
boot [8]. 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 Kupplungs-
fluid 75), available from your authorized KTM workshop.
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KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC
CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE
ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK-
SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.
NEVER REFILL WITH BRAKE FLUID.
Bleeding the hydraulic clutch *
If the clutch lever starts to feel unresponsive, the clutch control system needs
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to be bled. You will need a bleeder syringe (special tool) and biodegradable
hydraulic oil. Both are available from your KTM dealer.
Turn the handlebar until the master cylinder is in a horizontal position, remove
the screws [6], the cover [7] and the rubber boot [8].
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Fill the bleeder syringe [9] with biodegradable hydraulic oil (Motorex Kupplungs-
fluid 75). Remove the bleeder screw [10] from the slave cylinder and mount
the bleeder syringe. Press oil into the system until the oil runs out of the hole
[11] in the master cylinder without bubbles. Occasionally extract the oil from
the master 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).
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