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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Cleaning the air filter *
The air filter must be cleaned prior to each race or whenever dust has accu-
mulated. To clean, lift the filter box cover [1]
(see illustration) and pull off towards the front.
Detach the bottom of the filter retaining bracket [2], tilt aside and remove
the throttle cap [3] and the air filter [4] and filter support [5] from the filter
box. The SX models do not have a throttle cap.
– DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM-
AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY
MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID
BIO POWER).
– NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE,
DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR.
– DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL-
TER IS NOT MOUNTED CORRECTLY.
Thoroughly wash the air filter in special cleaning fluid and allow it to dry well.
Only press out the filter, do not wring it out under any circumstances. Oil the
dry air filter with a high-grade filter oil. Also clean the air filter box. Check
the carburetor collar for damage and that it is filled correctly.
Mount the air filter on the filter support. Insert the air filter and filter support
in the throttle cap and mount them in the filter box, aligning in a central posi-
tion, and fix with the filter retaining bracket.
10 mm
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Checking the adjustment of the hand decompression release cable *
Start the engine and, at idling speed, slowly pull the hand decompression
lever until you can feel the thumping of the rocker arm on the lever. The back-
lash until said thumping should be approx. 10mm, measured at the lever's
outer end. If necessary, correct this backlash.
To adjust, move back the protective cover [6], loosen the counter nut [7] and
correct the adjustment screw [8] accordingly. Tighten counter nut and push
back protective cover.
THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE CHECKED REGULARY.
IF THERE IS NO PLAY IN THE DEKO-LEVER, THIS CAN RESULT IN ENGINE
DAMAGE.
NOTE:
No adjustment need be made to the automatic decompressor.
Adjusting the throttle cables *
The throttle grip should always provide for a backlash of 3-5mm. Besides,
with the engine running, the idling speed must not change if you turn the
handlebar all the way to the left or right.
To adjust the throttle cables, dismount the seat and the tank together with
spoilers. Slide back the protection cover [9]. Loosen the counternut [10] and
turn the adjusting screw [11] accordingly. Turning the adjusting screw
counterclockwise will reduce the backlash, turning the adjusting screw clock-
wise will increase the backlash.
Tighten the counternut and check whether the throttle grip can be
actuated smoothly. Mount tank and seat.
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