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ENGLISH
18
PERIODIC MAINTENANCE SCHEDULE 2003
after / every
2500 km
or
25 hours
1. Service after
1000 km
or
10 hours
after / every
5000 km
or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM.
M
AINTENANCE WORK DONE BY
KTM
AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER
!
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and micro-filter ●●●
Clean oil screens and magnet of drain plug ●●●
Check oil lines for damage and kink-less arrangement ●●
Check and adjust spark plug, replace every 10,000 km ●
Check and adjust valve clearance ●●
Check engine fastening screws for tight fit ●●
Make sure all engine screws accessible from the outside are screwed tight
●●
Check carburetor connection boots for cracks and leaks ●
Check idle setting ●●
Check bleeder hoses for damage and kink-free arrangement ●●
Check cooling system for leaks, antifreeze protection ●●
Check exhaust system for leaks and suspension ●●
Check actuating cables for damage, smooth operation, and kink-less ●●
arrangement, adjust and lubricate
Clean air filter and air filter box ●
Check cables for damage and kink-less arrangement ●
Check headlamp adjustment ●
Check electrical system for function; (low/high beams, stop light, turn indicators, ●●
tell-tale lamps, horn,
emergency-off switch
)
Make sure all screws and nuts are tight
●●
Check brake fluid level, lining thickness, and brake discs ●●
Check brake lines for damage and leaks ●●
Check/adjust smooth operation, free travel of handbrake/footbrake levers ●●
Check screws of brake system for tight fit ●●
Check suspension strut and fork for leaks and proper function ●●
Check O-ring of suspension strut for wear ●
Clean dust sleeves ●
Bleed fork legs ●●
Check swinging-fork pivot ●
Check/adjust steering-head bearing ●●
Lubricate reversing lever ●
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, ●●
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join ●●
Check tire condition and inflation pressure ●●
Check chain and chain guides for wear, force fit and tension
●●
Check screws on pinion and chain sprocket for locking devices and a tight fit ●●
Lubricate chain ●●
Check wheel bearings and jerk damper for play ●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance ●
Perform complete suspension strut maintenance ●
Perform complete reversing lever maintenance ●
Replace glass-fiber yarn packing of main silencer ●
Clean and lubricate steering-head bearing and sealing elements ●
Clean and adjust the carburetor ●
Treat the electrical contacts and switches with contact spray ●
Change brake fluid ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURATOR
ENGINE
660 SMC
every 2 years
or 20000 km
at least
once a year
every 2500 km
or 25 hours