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MAINTENANCE WORK ON CHASSIS AND ENGINE
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XC-F/XCF-W/EXC-F
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SX-F
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Replacing the glassfiber yarn packing of the silencer *
Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the
filling checked regularly by an authorized KTM workshop (see Lubrication and
Service Chart). The insulating material fibers escape through the holes in the
perforated pipe with time, causing the silencer to „burn out“. In addition to
causing a higher noise-level, it will also affect the power characteristic. The
insulating material suitable for your exhaust is available from your authorized
KTM workshop.
By experience, the front glassfiber yarn packing(s) [1] need(s) to be replaced
more often than the rear silencing mat [2].
Take the silencer off and remove the front cap as well as the exhaust inner
pipe [3]. Pull the front glass fiber yarn packing out of the silencer. Clean the
front exhaust inner pipe.
To facilitate the mounting procedure, you can make a mounting tool out of
wood, plastic, or metal. Insert the mounting tool into the inner pipe and mount
the glassfiber packing. Push the inner pipe containing the packing into the
silencer such that the slot engages the web. Use a blunt ended object to stuff
the glassfiber yarn packing all the way into the silencer, and mount the front
cap.
To change the rear silencing mat, start by removing the front packing and the
inner exhaust pipe. Then, drill open the rivets and remove the end cap [4].
NOTE: In every exhaust repair procedure, the O-rings [5] must be replaced
by new ones. Glass fiber yarn packings are available from your licensed KTM
mechanic.
Make sure the caps are screwed on tightly. Mount the muffler stress-free before
tightening the fixing screws.
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.
Cleaning the spark arrester (XC-F/XCF-W USA) *
The spark arrester should be cleaned every time the glassfiber yarn filling is
changed or at least once annually.
For this purpose, dismount the silencer cap and remove any deposits that might
exist in region [A]. Renew the O-ring and mount the silencer cap.