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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 clockwise reduces the distance between the
clutch lever and the handlebar. Turning the adjusting screw counterclockwise
1
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.
Checking the oil level of the hydraulic clutch
To check the oil level in the master cylinder of the clutch remove the cover.
2
3
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.
4
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.
33
NEVER REFILL WITH BRAKE FLUID.
Checking and adjusting the choke cable play *
The choke lever must always have a play of approx. 4 mm (0.16 in).
IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER
SYSTEM CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CON-
SUMPTION, AN UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON
AND CYLINDER.
Remove the seat and tank to adjust.
Push the choke lever all the way to the front and slide the protecting cap [5]
from the adjusting part [6].
Loosen the lock nut [7] and correct the play by turning the adjusting part.
Tighten lock nut and slide protecting cap back on.
7
Mount the tank and seat.
6
5
Checking the adjustment of the hand decompression cable *
8
To check, set piston at compression, so that the valves are closed. While doing
10
this, slowly operate the kick starter until the clicking sound (disengaging) of
9
the automatic decompression release can be heard. Now it must be possible
to operate the decompression lever 10 mm (0.4 in) until resistance is felt
(the exhaust valves begin to open). To adjust move back the protective cover
[8], loosen the counter nut [9] and correct the adjusting screw [10] accord-
ingly. Tighten counter nut and push back protective cover.
10 mm
THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY
CHECKED (SEE MAINTENANCE WORK). A LACK OF PLAY IN THE HAND DECOM-
PRESSION LEVER CAN RESULT IN ENGINE DAMAGE.
NOTE: No adjustment need be made to the automatic decompressor.
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