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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
accumulated. To clean, lift the filter box cover (see illustration) and pull off
towards the front. Detach the filter retainer [1] at the bottom, tilt to the side
and remove the air filter [2] and the filter support [3] from the filter box.
Do not clean the air filter with fuel or petroleum since these will damage the
foam. KTM recommends the products made by Motorex (Bio Dirt Remover
and Liquid Bio Power) for air filter maintenance. for cleaning purposes and
to oil the air filter.
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. Mount the filter together with the
filter support in the filter box, making sure to center them, and fix them prop-
erly with the filter holding bracket.
Exhaust system
The silencer is filled with glass-fiber yarn for damping. When in use, the glass-
fiber yarn becomes loose or coked with oil carbon. This can lead to a power
loss and a reduction of the silencer damping. The glass-fiber yarn packing
can be replaced in a few easy steps.
To replace, remove the silencer from the vehicle and mark the position of the
outer tube [4] to the inner tube [5]. Remove screws [6] and the end cap [7].
Pull of the outer tube and remove the old glass-fiber yarn packing [8] from
the inner tube. Thoroughly clean all parts.
To assemble, mount a new glass-fiber yarn packing onto the inner tube (see
illustration) and slide into the outer tube. Mount end cap and fix with
screws [6]. Before tightening the screws, turn the outer tube until they match
the positions you marked. Mount the silencer and check the exhaust system
for tightness.
Note: Glass fiber yarn packages are offered by your licensed KTM dealer.
The exhaust system becomes very hot while the motorcycle is running. To avoid
burns do not start work on the exhaust system until it has properly cooled down.
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