KTM 300 EXC, Repair Manual

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29 SERVICE SCHEDULE
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29.1 Service schedule
Every 40 operating hours/after every race
Every 20 operating hours
Check that the electrical equipment is functioning properly.
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Check and charge the battery.
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Check the front brake linings. ( p. 106)
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Check the rear brake linings. ( p. 111)
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Check the brake discs. ( p. 92)
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Check the brake lines for damage and leakage.
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Check the rear brake fluid level. ( p. 114)
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Check the free travel of the foot brake lever. ( p. 113)
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Check the frame and swingarm.
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Check the swingarm bearing.
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Check the heim joints at the top and bottom of the shock absorber.
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Check the tire condition. ( p. 91)
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Check the tire air pressure. ( p. 91)
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Check the wheel bearing for play.
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Check the wheel hubs.
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Check the rim run-out.
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Check the spoke tension. ( p. 92)
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Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 98)
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Check the chain tension. ( p. 97)
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Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
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Check/correct the fluid level of the hydraulic clutch. ( p. 194)
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Check the front brake fluid level. ( p. 109)
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Check the free travel of the hand brake lever. ( p. 108)
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Check the play of the steering head bearing. ( p. 53)
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Change the spark plug and spark plug connector.
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Check the intake diaphragm.
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Check the exhaust control for functioning and smooth operation.
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Check the clutch.
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Change the gear oil. ( p. 199)
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Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing.
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Check the antifreeze and coolant level. ( p. 195)
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Check the cables for damage and routing without sharp bends.
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Check that the throttle cables are undamaged, routed without sharp bends and set correctly.
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Clean the air filter and air filter box. ( p. 84)
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Change the glass fiber yarn filling of the main silencer. ( p. 81)
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Check the screws and nuts for tightness.
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Check the headlight setting. ( p. 117)
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Check the idle.
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Final check: Check the vehicle for safe operation and take a test ride.
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Make the service entry in KTM DEALER.NET and in the service record.
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Periodic interval