Changing The Original Position Of The Clutch Lever; Checking The Oil Level Of The Hydraulic Clutch; Bleeding Of The Hydraulic Clutch; Exhaust System - KTM 125 SX Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
2
40
5
SX
9
10
1
3
4
6
7
EXC
8
9
8
10

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.

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 SAE 10 biodegradable hydraulic oil (Motorex Kupplungs-
fluid 75), available from your authorized KTM workshop.
KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON-
TROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER
REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
Bleeding 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
the screws [2], the cover [3] and the rubber boot [4].
Fill the bleeder syringe [5] with biodegradable hydraulic oil (Motorex Kupplungs-
fluid 75). 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 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).

Exhaust system *

Silencers whose cap [8] is detachable are filled with glass-fiber yarn. Let this
package be ckecked at least after 4000 km or at once a year. Glass-fiber yarn
that is too loose may cause a drop in performance and curtail the silencer's
silencing effect.
To replace the glass-fiber yarn packing [9], remove the silencer cap and pull
off the outer tube [10]. Use adhesive tape to attach the new glass-fiber yarn
packing to the inner tube, and slide on outer tube. Mount silencer cap.
Glass-fiber yarn packings are available at your authorized KTM dealer.
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.
»