Periodic Maintenance Schedule - KTM 660 RALLY 2004 Owner's Manual

A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, fine filter and micro 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 (every 6000 km)
Check engine fastening screws for tight fit
Make sure all engine screws accessible from the outside are screwed tight
Clean carburetor, 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 operation
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them
Check fluid level of the clutch master cylinder
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
18
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)
Make sure all screws and nuts are tight.
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 screws of brake system for tight fit
Check suspension strut and fork for leaks and proper operation
Check O-ring of suspension strut for wear
Clean fork dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension.
Check screws on pinion and chain sprocket for locking devices and a tight fit.
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
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
Clean or replace all fuel filters
Replace the needle jet, jet needle and slide sealing plate

PERIODIC MAINTENANCE SCHEDULE

660 RALLY 2004
2nd Service after
1st Service
after 3000 km, then
every 2000 km
1000 km
at least Every
once a year 10,000 km