Cleaning The Air Filter; Replacing The Glass Fiber Yarn Packing Of The Silencer; Cleaning The Spark Arrestor (Exc Usa) - KTM 400 SX RACING 2000 Owner's Handbook Manual

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Cleaning the air filter *

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A dirty air filter impairs the air-flow rate, reduces the engine performance,
and increases the fuel consumption. In extreme cases, dirt may even get
into the engine and cause damage. Therefore, change the air filter in
regular intervals.
For this purpose, rotate the two quick-release fasteners
wise and pull them outward up to the stop, pull the filter box cover forward
and remove it. Unhook the filter holding brackets
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them sideways and take the air filter
out of the filter box.
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Thoroughly wash the air filter in special cleaning fluid and allow it to dry
well. Only press out the filter, do not wring it out under any circumstances.
Oil the dry air filter with a high-grade filter oil. Also clean the air filter box.
Check carburetor collar for damage and that it is filled correctly.
Mount the air filter on the filter support. Apply grease to the face
filter to improve its sealing properties. Mount the filter together with the fil-
ter support in the filter box, making sure to properly center them, and fix
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them with the filter holding bracket.

Replacing the glass fiber yarn packing of the silencer *

Aluminum silencers are filled with glass fiber yarn to muffle noise. The
effect of heat causes the glass fiber yarn to become loose. This may lead to
a loss of performance and reduce the silencer's muffling power. By experi-
ence, the front glass fiber yarn packing
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than the rear silencing mat
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For this purpose, remove the silencer from the vehicle and dismount the
front cap
exhaust pipe
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To facilitate the mounting procedure, you can make a mounting tool
of wood, plastic, or metal. Insert the mounting tool into the inner pipe and
mount the glass fiber packing. Push the inner pipe containing the packing
into the silencer such that the slot engages the web
object to stuff the glass fiber yarn packing all the way into the
silencer, and mount the front cap.
To change the rear silencing mat, start by removing the front packing and
the inner exhaust pipe. Then, drill open the rivets and remove the end cap.
NOTE!
In every exhaust repair procedure, the O-rings must be replaced by new
ones. Glass fiber yarn packings are available at your licensed KTM
mechanic.
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T
HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING
AVOID BURNS
COOLED DOWN
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Cleaning the spark arrester (EXC USA) *
The spark arrester should be cleaned every time the glass fiber yarn filling is
changed or at least once annually.
For this purpose, dismount the silencer cap and remove any deposits that
might exist in region
! CAUTION
O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE
. KTM
THE FOAM RECOMMENDS THE PRODUCTS MADE BY
.„A C
TER MAINTENANCE CTION LEANER
F " .
LUID TO OIL THE AIR FILTER
EVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS
AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR
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.
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. Pull the front glass fiber yarn packing together with the inner
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out of the silencer. Clean the front inner exhaust pipe.
WARNING
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O NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY
.
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. Renew the O-ring and mount the silencer cap.
1 counter-clock-
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at the bottom, swing
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together with the filter support
!
PUTOLINE
FOR AIR FIL
"
FOR CLEANING PURPOSES AND
. O
THERWISE
.
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needs to be replaced more often
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. Use a blunt ended
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CTION
,
DUST
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of the
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out
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