ENGLISH
20
PERIODIC MAINTENANCE SCHEDULE 2003
1. service after
3 hours
or
20 l fuel
after/every
15 hours
or
100 l fuel
IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.
S
ERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN
2
HOURS OR
15
LITERS OF FUEL
.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER.
A clean motorcycle can be checked more quickly which saves money!
Change engine oil, short and long oil filters ●●
Clean oil screen and drain plug magnet ●●
Check oil lines for damage or bends ●●
Replace spark plug (after 30 hours)
Check and adjust valve clearance ●●
Check engine mounting bolts for tightness ●●
Check carburetor connection boot for cracks and leaks ●
Check idle speed setting ●●
Check vent hoses for damage or bends ●●
Check cooling system for leaks, check quantity of antifreeze ●●
Check exhaust system for leaks and fitment ●
Check cables for damage, smooth operation and bends ●●
adjust and lubricate
Check fluid level of the clutch master cylinder ●●
Clean air filter and filter box ●
Check electric wires for damage and bends ●
Check headlamp setting ●
Check function of electric systems (low high beam, brake light, indicator lamps, ●●
speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, brake discs ●●
Check brake lines for damage and leaks ●●
Check/function smooth operation and adjust free travel of handbrake/foot brake lever ●●
Check tightness of brake system screws ●●
Check shock absorber and fork for leaks and function ●●
Clean fork dust bellows ●
Bleed fork legs ●
Check swing arm bearings ●
Check/adjust steering head bearings ●●
Check tightness of chassis screws ●●
(triple clamps, fork leg axle passage)
Check spoke tension and rim joint ●
Check tires and air pressure ●●
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension ●●
Lubricate chain ●●
Check clearance of wheel bearings ●●
IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER
Complete maintenance of fork ●
Complete maintenance of shock absorber ●
Clean and grease steering head bearings and gasket elements ●
Clean and adjust carburetor ●
Replace glass fibre yarn filling of the exhaust main silencer ●
Treat electric contacts and switches with contact spray ●
Treat battery connections with contact grease ●
Change hydraulic clutch fluid ●
Change brake fluid ●
WHEELS CHASSIS BRAKES ADD- ON PARTS
CARBURETOR
ENGINE
250/450/525 SX/MXC/EXC RACING
at least
once a year
