Replacing The Glass Fiber Yarn Packing Of The Silencer; Checking The Adjustment Of The Hand Decompression Release Cable; Changing The Original Position Of The Clutch Lever; Checking The Oil Level Of The Hydraulic Clutch - KTM 660 SMC SUPERMOTO 2003 Supplement To Owners Handbook

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10 mm
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8
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Replacing the glass fiber yarn packing of the silencer *

The silencer is filled with glass-fiber yarn to reduce the noise. The effect of
heat causes the glass fiber yarn to become loose. This may lead to a loss of
performance and reduce the silencer's muffling power.
To replace the glass-fiber yarn, remove the silencer. Bore out all 8 rivets and
disassemble the silencer. Clean parts and check for cracks.
For easy mounting of the glass-fiber yarn pack, wrap fabric tape around the
rear end of the exhaust pipe
exhaust pipe. Mount the outer pipe and fix in the front with 4 rivets. Center
the exhaust pipe. Mount the end cap and the rivets.
WARNING
T
HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING
D
AVOID BURNS O NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY
.
COOLED DOWN
Checking the adjustment of the hand decompression release
cable *
To check, set piston at compression, so that the valves are closed. While
doing this, slowly kick the kick starter through its stroke until the clicking
sound (disengaging) of the automatic decompression release can be heard.
Now the deko-lever must be operated 10 mm until resistance is felt (the
exhaust valves begin to open). To adjust move back the protective cover
loosen the counter nut 3 and correct the adjustment screw
Tighten counter nut and push back protective cover.
!
I -
F THERE IS NO PLAY IN THE DEKO
NOTE:
No adjustment need be made to the automatic decompressor.

Changing the original position of the clutch lever

5
The adjusting screw 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 counterclock-
wise increases the distance between the clutch lever and the handlebar.
!
A
DJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS
O
NLY 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
8
the rubber boot . The oil level in the horizontal-standing master cylin-
der should be 4 mm below the upper edge.
If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell
Naturelle HF-E15).Biodegradable hydraulic oil is available from your
KTM dealer (50ml).
!
– KTM
USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL
N
EVER MIX THIS OIL WITH MINERAL OIL
– O SAE 10
NLY USE BIODEGRADABLE HYDRAULIC OIL
E15)
TO FILL THE HYDRAULIC CLUTCH
.
BRAKE FLUID
1
. Slide the glass-fiber yarn pack onto the
CAUTION
,
LEVER THIS CAN RESULT IN ENGINE DAMAGE
CAUTION
6 7
and cover
CAUTION
.
( . . S
E G HELL
. N
EVER USE MINERAL HYDRAULIC OIL OR
.
TO
2
,
4 accordingly.
!
.
!
.
.
together with
!
.
N HF-
ATURELLE