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KTM 450 EXC Racing Manual

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ENGLISH
23
PERIODIC MAINTENANCE »
IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel.
Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
250/400/450/525 SX/XC/EXC 2006
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st service
after 3 hours
or
20 l fuel
every
15 hours
or
100 l fuel
ENGINE
Change engine oil, short and long oil filters
z z
Clean oil screen and drain plug magnet
z z
Check oil lines for damage or bends
z z
Replace spark plug (after 30 hours)
Check and adjust valve clearance
z z
Check engine mounting bolts for tightness
z z
Clean the spark-plug connector and check for a tight fit
z z
Check the screws on the kick starter and shift lever for a tight fit
z z
CARBURETOR
Vergasermanschetten auf Risse und Dichtheit prüfen
z
Check idle speed setting
z z
Entlüftungsschläuche auf Beschädigung und knickfreie Verlegung prüfen
z z
ADD- ON PARTS
Check cooling system for leaks, check quantity of antifreeze
z z
Check exhaust system for leaks and fitment
z
Check cables for damage, smooth operation and bends
adjust and lubricate
z z
Check fluid level of the clutch master cylinder
z z
Clean air filter and filter box
z
Check electric wires for damage and bends
z
Check headlamp setting
z
Check function of electric systems (low high beam, brake light, indicator lamps,
speedometer illumination, horn, emergency OFF switch or button
z z
BRAKES
Check brake fluid level, lining thickness, brake discs
z z
Check brake lines for damage and leaks
z z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
z z
Check the screws and guide bolts on the brake system for a tight fit
z z
CHASSIS
Check shock absorber and fork for leaks and function
z z
Clean fork dust bellows
z
Bleed fork legs
z
Check swing arm bearings
z
Check/adjust steering head bearings
z z
Check tightness of chassis screws
(triple clamps, fork leg axle passage, swingarm, shock aborber)
z z
WHEELS
Check spoke tension and rim joint
z z
Check tires and air pressure
z z
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
z z
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
z z
Check clearance of wheel bearings
z z
250/400/450/525 SX/XC/EXC 2006
IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER
at least
once a year
every
2 years
Complete maintenance of fork
z
Complete maintenance of shock absorber
z
Clean and grease steering head bearings and gasket elements
z
Clean and adjust carburetor
z
Treat electric contacts and switches with contact spray
z
Treat battery connections with contact grease
z
Change hydraulic clutch fluid
z
Change hydraulic clutch fluid
z
Clean Sparkarrestor (XC/EXC USA)
z
… 24 …


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