KTM 400-660 LC4 1998-2005, Repair Manual

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12-20E
PERIODIC MAINTENANCE SCHEDULE 2002
1. Service
after
1000 km
2. Service after
5000 km, then
every 5000 km or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S
ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN
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 fine filter
● ●
Clean oil screens and magnet of drain plug
● ●
Check oil lines for damage and kink-less arrangement
● ●
Check and adjust spark plug, replace it every 10,000 km
●
Check and adjust valve clearance
● ●
Check engine fastening bolts for tight fit
● ●
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 radiator fan for proper function
●
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, ● ●
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
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 bolts 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 ● ●
Service eccentric for chain tension
●
Lubricate reversing lever
●
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
● ●
swinging-fork pivot, reversing lever, suspension strut)
Check tire condition, inflation pressure, and rim condition
● ●
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
● ●
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 the silencers
●
Clean and lubricate steering-head bearing and sealing elements
●
Clean and adjust the carburetor
●
Treat the electrical contacts and switches with contact spray
●
Treat battery connections with contact grease
●
Change the brake fluid
●
WHEELS
CHASSIS
BRAKES
ADD-ON-P
AR
TS
CARBUT
ATOR
ENGINE
640 Duke II
every 2 years
or 20000 km
at least
once a year