KTM 400-660 LC4 1998-2005 Repair Manual page 325

12-9E
KTM
KTM
PERIODIC MAINTENANCE SCHEDULE
rider dealer
Duke 5.99
IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM
(3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE
Check engine oil level
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Maintain chain tension eccentrics
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreezer
Check cooling system for leaks – visual check
Check exhaust system for leakage
Check exhaust brackets
Clean spark arrestor discs (USA model)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check wear of brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen breather screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Check O-ring of the shock absorber for wear
Service the shock absorber
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points