Periodic Maintenance Schedule 2004 - KTM 250 EXC RACING 2004 Owner's Manual

PERIODIC MAINTENANCE SCHEDULE 2004

A clean motorcycle can be checked more quickly which saves money!
Change engine oil, short and long oil filters
Clean oil screen and drain plug magnet
Check oil lines for damage or bends
Replace spark plug (after 30 hours)
Check and adjust valve clearance
Check engine mounting bolts for tightness
Check carburetor connection boot for cracks and leaks
Check idle speed setting
Check vent hoses for damage or bends
Check cooling system for leaks, check quantity of antifreeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation and bends
adjust and lubricate
Check fluid level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
20
Check function of electric systems (low high beam, brake light, indicator lamps,
speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, brake discs
Check brake lines for damage and leaks
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
Check tightness of brake system screws
Check shock absorber and fork for leaks and function
Clean fork dust bellows
Bleed fork legs
Check swing arm bearings
Check/adjust steering head bearings
Check tightness of chassis screws
(triple clamps, fork leg axle passage)
Check spoke tension and rim joint
Check tires and air pressure
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
Lubricate chain
Check clearance of wheel bearings
I R
MPORTANT ECOMMENDED
Complete maintenance of fork
Complete maintenance of shock absorber
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
Replace glass fibre yarn filling of the exhaust main silencer
Treat electric contacts and switches with contact spray
Treat battery connections with contact grease
Change hydraulic clutch fluid
Change brake fluid
IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.
S
ERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN
M
AINTENANCE WORK DONE BY
M W
AINTENANCE
KTM
AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER
C
ORK THAT CAN BE ARRIED
2
HOURS OR
250/450/525 SX/MXC/EXC RACING
1. service after after/every
3 hours 15 hours
or or
20 l fuel 100 l fuel
O E O
UT BY XTRA RDER
at least
once a year
15
LITERS OF FUEL
.
.