KTM 660 RALLY 2004 User Manual

ENGLISH
18
PERIODIC MAINTENANCE SCHEDULE
1st Service
after
1000 km
2nd Service after
3000 km, then
every 2000 km
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 ●●
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 ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURETOR
ENGINE
Every
10,000 km
at least
once a year
660 RALLY 2004

KTM 660 RALLY 2004 Specifications

General

Brand	KTM
Model	660 RALLY 2004
Category	Motorcycle
Language	English