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38
MAINTENANCE WORK ON CHASSIS AND ENGINE
»
5W/40
JASO T903 MA
TEMPERATURE
5°C
41°F
10W/50
Engine oil
Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four-stroke motorcycles - the
JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds. Most motorcycle engines also use the same oil to lubricate the transmission and the clutch. The JASO MA standard responds to these special requirements.
Only use fully synthetic engine oils that meet the JASO MA quality requirements
(see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F).
1
1
2
250 SX-F
450 SX-F
2
Insufficient oil or poor quality oil results in premature wear of the engine.
Changing the engine oil *
NOTE: When changing the engine oil, it is necessary to clean the short and long oil screens (450 SX-F only one oil screen) and to replace the oil filter.
Engine oil has be changed with the engine at an operating temperature.
An engine at operating temperature and the engine oil it contains are very hot
– do not burn or scald yourself.
Place the motorcycle on a horizontal surface, remove the plug [1] and allow the oil to drain into a receptacle.
Clean plug (with magnet) thoroughly.
Once the entire oil has been drained, clean the sealing surface, mount the plug together with the sealing ring and tighten it to 20 Nm.
CLEANING THE SHORT OIL SCREEN (250 SX-F) AND OIL SCREEN (450 SX-F)
The oil screen is accommodated in the hex-socket plug [3] at the engine bottom.
Insert a pin-type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug. Dismount the oil screen, clean the components thoroughly and blow compressed air through them. Check the O-rings for damage and, if necessary, replace them. Mount the oil screen together with the plug again and tighten the plug to 10 Nm (250 SX-F) or 30
Nm (450 SX-F).
CLEANING THE LONG OIL SCREEN (250 SX-F)
The long oil screen is accommodated in the hexagon plug [3] adjacent to the engine number. Dismount the plug together with the oil screen, clean the components thoroughly and blow compressed air through them. Check the Orings for damage and, if necessary, replace them.
3
4
To mount the long oil screen [4], place it on an approx. 300 mm (12 in) long pin-type key or a similar tool. Insert the pin-type key through the opening into the bore of the opposite engine casing wall. Then, push the oil screen into the engine casing as far as possible. Remove the pin-type key, mount the plug and tighten it to 15 Nm.
The oil screen is mounted slightly downwards, incorrectly fitted, the screen looses its function and this can cause increased engine wear.
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Table of contents
- 3 IMPORTANT INFORMATION
- 6 SERIAL NUMBER LOCATIONS
- 6 Chassis number
- 6 Engine number, engine type
- 6 OPERATION INSTRUMENTS
- 6 Clutch lever
- 6 Hot start lever
- 7 Hand brake lever
- 7 Short circuit button
- 7 Starter button (450 SX-F)
- 7 Filler cap
- 7 Fuel tap
- 8 Choke
- 8 Shift lever
- 8 Kickstarter (250 SX-F)
- 8 Foot brake pedal
- 8 Plug in stand
- 9 Compression damping of fork
- 9 Rebound damping of fork
- 9 Compression damping of shock absorber
- 10 Rebound damping of shock absorber
- 11 MOTORCYCLE
- 11 Instructions for initial operation
- 11 Running in the Racing models
- 12 DRIVING INSTRUCTIONS
- 12 Check the following before each start
- 13 Starting when the engine is cold
- 13 Starting when the engine is warm
- 13 What to do when the engine is "flooded
- 14 Starting off
- 14 Shifting/Riding
- 14 Braking
- 14 Stopping and parking
- 15 PERIODIC MAINTENANCE
- 17 MAINTENANCE WORK ON CHASSIS AND ENGINE
- 17 Pivot bearing
- 18 Basic suspension setup for the weight of the driver
- 18 Checking the shock absorber and spring
- 18 Determining the static sag of the shock absorber
- 18 Determining the riding sag of the shock absorber
- 19 Checking the basic setup of the telescopic fork
- 19 Changing the spring preload on the telescopic fork
- 19 Replacing fork springs
- 19 Breather plug front fork
- 19 Cleaning the dust sleeves of the telescopic fork
- 20 Changing the fork offset (caster)
- 21 Checking and adjusting the steering head bearing
- 21 Checking the throttle cable installation
- 22 How to change the handlebar position
- 22 Check chain tension
- 23 Correct chain tension
- 23 sprocket teeth
- 24 Chain maintenance
- 24 Chain wear
- 25 General information about KTM disc brakes
- 26 Adjusting the free travel at the hand brake lever
- 26 Checking the brake fluid level - front brake
- 26 Refilling the front brake fluid reservoir
- 26 Checking the front brake pads
- 27 Replacing the front brake pads
- 27 Checking the rear brake fluid level
- 27 Refilling the rear brake fluid reservoir
- 28 Changing the basic position of the foot brake pedal
- 28 Checking the rear brake pads
- 28 Replacing the rear brake pads
- 29 Dismounting and mounting the front wheel
- 30 Dismounting and mounting the rear wheel
- 30 Checking spoke tension
- 31 Tires, air pressure
- 31 Battery (450 SX-F)
- 32 Charging the battery (450 SX-F)
- 32 Fuse (450 SX-F)
- 33 Cooling system
- 33 Checking the coolant level
- 33 Bleeding the cooling system
- 35 Cleaning the air filter
- 35 Adjusting the throttle cables
- 36 Changing the original position of the clutch lever
- 36 Checking the oil level of the hydraulic clutch
- 36 Bleeding of the hydraulic clutch
- 37 Carburetor - Adjust idling
- 37 Basic information on carburetor wear
- 37 Checking the float level (float height)
- 38 Draining the float chamber of the carburetor
- 38 Checking the engine oil level
- 39 Engine oil
- 39 Changing the engine oil
- 40 Changing the oil filter
- 41 TROUBLESHOOTING
- 43 CLEANING
- 43 STORAGE
- 44 TECHNICAL DATA - ENGINE
- 45 TECHNICAL DATA - CHASSIS
- 48 HEAD WORK INDEX