ENGLISH
18
PERIODIC MAINTENANCE SCHEDULE
1st Service
after
1000 km
2nd Service after
3000 km, then
every 2000 km
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, fine filter and micro filter
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Clean oil screens and magnet of drain plug
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Check oil lines for damage and kink-less arrangement
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Check and adjust spark plug, replace it every 10,000 km
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Check and adjust valve clearance (every 6000 km)
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Check engine fastening screws for tight fit
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Make sure all engine screws accessible from the outside are screwed tight
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Clean carburetor, check carburetor connection boots for cracks and leaks
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Check idle setting
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Check bleeder hoses for damage and kink-free arrangement
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Check cooling system for leaks, antifreeze protection
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Check radiator fan for proper operation
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Check exhaust system for leaks and suspension
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Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them
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Check fluid level of the clutch master cylinder
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Clean air filter and air filter box
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Check cables for damage and kink-less arrangement
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Check headlamp adjustment
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Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
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tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all screws and nuts are tight.
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Check brake fluid level, lining thickness, and brake discs
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Check brake lines for damage and leaks
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Check/adjust smooth operation, free travel of handbrake/footbrake levers
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Check screws of brake system for tight fit
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Check suspension strut and fork for leaks and proper operation
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Check O-ring of suspension strut for wear
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Clean fork dust sleeves
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Bleed fork legs
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Check swinging-fork pivot
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Check/adjust steering-head bearing
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Lubricate reversing lever
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Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,
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swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim joint
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Check tire condition and inflation pressure
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Check chain and chain guides for wear, force fit and tension.
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Check screws on pinion and chain sprocket for locking devices and a tight fit.
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Lubricate chain
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Check wheel bearings and jerk damper for play
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IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
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Perform complete suspension strut maintenance
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Perform complete reversing lever maintenance
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Clean and lubricate steering-head bearing and sealing elements
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Clean and adjust the carburetor
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Treat the electrical contacts and switches with contact spray
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Treat battery connections with contact grease
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Change the brake fluid
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Clean or replace all fuel filters
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Replace the needle jet, jet needle and slide sealing plate
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WHEELS
CHASSIS
BRAKES
ADD-ON-P
AR
TS
CARBURETOR
ENGINE
Every
10,000 km
at least
once a year
660 RALLY 2004
