Check engine oil level
ⅷ
Change engine oil
ⅷⅷ ⅷ
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
ⅷ
Change oil filter unit
ⅷⅷⅷ
Change microfilter
ⅷⅷ
Check oil lines for leakage and proper instalment
ⅷⅷ
Check valve clearance
ⅷⅷ
Clean spark plug and adjust electrode gap
ⅷ
Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance
ⅷ
Drain and clean carburator float bowl
ⅷⅷⅷ
Adjust idling
ⅷ
Check breather hoses of engine gase and gas tank for correct position without buckles
ⅷⅷ
Clean air filter and air filter box
ⅷⅷⅷ
Check sprockets, chain guides and chain for wear
ⅷⅷⅷ
Clean and lube chain
ⅷⅷ ⅷ
Check chain tension
ⅷⅷⅷ
Check cooling liquid level
ⅷⅷⅷ
Check quality of antifreeze
ⅷ
Check cooling system for leaks
ⅷⅷⅷ
Check exhaust system for leakage
ⅷ
Change exhaust muffler packing (aluminium-muffler)
ⅷⅷ
Check exhaust brackets
ⅷⅷ
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
ⅷⅷⅷ
Change brake fluid
ⅷ
Check brake pad thickness
ⅷⅷ
Check brake discs
ⅷ
Check condition and correct instalment of brake hoses
ⅷⅷⅷ
Check freeplay and easy operation of hand brake lever and foot brake lever
ⅷⅷⅷ
Check adjustment and function of fork
ⅷⅷ
Check fork for leaks
ⅷ
Loosen breather screws at fork legs (overpressure)
ⅷ
Change fork oil
ⅷ
Perform a full maintenance job for the telescopic fork
ⅷ
Clean dust scrabber on forks
ⅷⅷⅷ
Check steering head bearing clearance / adjust
ⅷⅷ
Clean and grease steering head bearings and its seals
ⅷ
Check adjustment and funktion of shock absorber
ⅷⅷ
Check O-ring of the shock absorber for wear
ⅷⅷ
Servicing the shock absorber
ⅷ
Grease lubricating nipple of the Pro Lever suspension system
ⅷ
Disassemble the Pro Lever suspension system and perform a full maintenance job on it
ⅷ
Servicing swingarm pivots
ⅷ
Check tightness of spokes and rim join
ⅷⅷⅷ
Check wheel bearings for clearance
ⅷⅷ
Check tire condition and air pressure
ⅷⅷ
Check cables for damage and easy working
ⅷⅷ
Lube and adjust cables
ⅷⅷ ⅷ
Check the electrical system
ⅷⅷⅷ
Check adjustment of head light
ⅷ
Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray
ⅷⅷ
Check all screws, nuts and hose clamps for proper tightness
ⅷⅷⅷ
Grease or lube all pivot points and sliding components
ⅷⅷ ⅷ
PERIODIC MAINTENANCE SCHEDULE
before each start
after washing
1st service, after
1000 km (600 miles)
or 10 hours
after 2500 km
(1500 miles)
or 25 hours
after 5000 km
(3000 miles) or
once a year
at least once a year
KTM
rider
KTM
dealer
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITI-
VE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT
AFTER EACH RIDE OR RACE
2.99
620 SX
400/540 SXC
400/620 SC
37
