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Check engine oil level
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Change engine oil
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Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
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Change oil filter unit
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Change microfilter
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Check oil lines for leakage and proper instalment
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Check valve clearance
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Clean spark plug and adjust electrode gap
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Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance
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Drain and clean carburator float bowl
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Adjust idling
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Check breather hoses of engine gase and gas tank for correct position without buckles
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Clean air filter and air filter box
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Check sprockets, chain guides and chain for wear
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Clean and lube chain
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Check chain tension
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Check cooling liquid level
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Check quality of antifreeze
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Check cooling system for leaks
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Check exhaust system for leakage
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Change exhaust muffler packing (aluminium-muffler)
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Check exhaust brackets
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Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
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Change brake fluid
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Check brake pad thickness
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Check brake discs
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Check condition and correct instalment of brake hoses
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Check freeplay and easy operation of hand brake lever and foot brake lever
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Check adjustment and function of fork
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Check fork for leaks
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Loosen breather screws at fork legs (overpressure)
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Change fork oil
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Perform a full maintenance job for the telescopic fork
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Clean dust scrabber on forks
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Check steering head bearing clearance / adjust
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Clean and grease steering head bearings and its seals
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Check adjustment and funktion of shock absorber
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Check O-ring of the shock absorber for wear
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Servicing the shock absorber
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Grease lubricating nipple of the Pro Lever suspension system
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Disassemble the Pro Lever suspension system and perform a full maintenance job on it
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Servicing swingarm pivots
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Check tightness of spokes and rim join
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Check wheel bearings for clearance
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Check tire condition and air pressure
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Check cables for damage and easy working
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Lube and adjust cables
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Check the electrical system
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Check adjustment of head light
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Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray
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Check all screws, nuts and hose clamps for proper tightness
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Grease or lube all pivot points and sliding components
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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
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