ENGLISH
16
PERIODIC MAINTENANCE SCHEDULE
»
A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st Service
after
1000 km
2nd Service after
5000 km, then
every 5000 km
or once a year
ENGINE
Change engine oil, oil filters, and fine filter
z
z
Clean oil screens and magnet of drain plug
z
z
Check oil lines for damage and kink-less arrangement
z
z
Check and adjust spark plug, replace it every 10,000 km
z
Check and adjust valve clearance
z
z
Check engine fastening screws for tight fit
z
z
Make sure all engine screws accessible from the outside are screwed tight
z
z
CARBURATOR
Check carburetor connection boots for cracks and leaks
z
Check idle setting
z
z
Check bleeder hoses for damage and kink-free arrangement
z
z
ADD-ON-PARTS
Check cooling system for leaks, antifreeze protection
z
z
Check radiator fan for proper function
z
Check exhaust system for leaks and suspension
z
z
Check actuating cables for damage, smooth operation, and kink-less arrangement,
z
z
adjust and lubricate
Check fluid level of the clutch master cylinder
z
z
Clean air filter and air filter box
z
Check cables for damage and kink-less arrangement
z
Check headlamp adjustment
z
Check electrical system for function (low/high beams, stop light, turn indicators,
z
z
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Make sure all screws and nuts are tight
z
z
BRAKES
Check brake fluid level, lining thickness, and brake discs
z
z
Check brake lines for damage and leaks
z
z
Check/adjust smooth operation, free travel of handbrake/foot brake levers
z
z
Check screws of brake system for tight fit
z
z
CHASSIS
Check suspension strut and fork for leaks and proper function
z
z
Check O-ring of suspension strut for wear
z
Clean dust sleeves
z
Bleed fork legs
z
z
Check swinging-fork pivot
z
z
Check/adjust steering-head bearing
z
z
Service eccentric for chain tension
z
Lubricate reversing lever
z
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,
z
z
swinging-fork pivot, reversing lever, suspension strut)
WHEELS
Check tire condition, inflation pressure, and rim condition
z
z
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
z
z
Lubricate chain
z
z
Check wheel bearings and jerk damper for play
z
640
DUKE II
2005
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE
BY THE RIDER!
