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16
MAINTENANCE WORK ON CHASSIS AND ENGINE
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Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put motorcycle
on the stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the three clamp screws
[1] of the top triple clamp and turn steering stem bolt clockwise [2] until there
is no more play. Don’t tighten the steering stem bolt all the way, otherwise
the bearings will be damaged. With a plastic hammer, lightly rap on the triple
clamp to release tension. Retighten the three clamp screws to 25 Nm.
If the steering head bearing is not adjusted to be free of play, the motorcycle
will exhibit unsteady driving characteristics and can get out of control.
If you drive with play in the steering head bearing for longer periods, the bear-
ings and subsequently the bearing seats in the frame will be destroyed.
The steering head bearings should be regreased at least once a year
(i.e. Motorex Long Term 2000).
All maintenance and adjustment operations that are marked with an asterisk * require specialist knowledge. For your own security, let
these tasks be carried out by a ktm-dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff.
– When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings,
carburetor, electric connectors, etc.
– When transporting your KTM, ensure that it is held upright with restraining straps or other mechanical fastening devices and that
the fuel tap is in the OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank.
– Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or
longer screws can cause leaks in the tank through which fuel can flow out.
– Do not use toothed washers or spring rings with the engine fastening screws, as these work into the frame parts and keep working
loose. Instead, use self-locking nuts.
– Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned.
– Dispose of Oils, fatty matters, filters, fuels, washing detergents, etc. properly.
– Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter of used oil contam-
inates 1,000,000 liters of water.
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Breather plug front fork
The telescopic fork should be ventilated at regular intervals. Jack up the motor-
cycle until the front wheel no longer touches the ground. Unscrew vent screws
[3] several turns to let any excess pressure escape from the inside of the fork.
Excessive pressure in the interior of the fork can cause leaks in the fork. If
your fork is leaking, it is recommended to open the breather plugs before hav-
ing the seals replaced.
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