Changing The Original Position Of The Clutch Lever; Checking The Oil Level Of The Hydraulic Clutch; Bleeding Of The Hydraulic Clutch - KTM 400 EXC Owner's Manual

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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.
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ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER-
TAIN 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
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boot [4]. The oil level in the horizontal-standing master cylinder should be 4
mm below the upper edge.
If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex
Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM
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dealer (50ml).
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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-
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SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.
NEVER REFILL WITH BRAKE FLUID.

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) and biodegradable
hydraulic oil. Both are available from your KTM dealer.
Turn the handlebar until the master cylinder is in a horizontal position, remove
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the screws [2], the cover [3] and the rubber boot [4].
Fill the bleeder syringe [6] with biodegradable hydraulic oil (Motorex Kupplungs-
fluid 75). Remove the bleeder screw [5] 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
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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).
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.
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