KTM RFS Dirt Bike Setup & Maintenance by Jon Delameter on 4Strokes.com
4Strokes.com KTM Technical: KTM RFS Setup & Maintenance
by Jon Delameter
The picture to the right is my 2002 KTM 400 EXC stripped down ready
for cleaning, greasing and re-torquing after 800~odd miles. This does not really
take that long to do once you have committed to tearing your bike apart. I sure
found a few eyebrow-raisers too, like the motor-mount bolts that were finger-tight
and the near-dry steering head bearings, as with most bikes.
This is information compiled by other owners from experience. The
time you invest when your bike is new (or nearly new) to perform these tasks
WILL pay off in a year or two after you have put a lot of hard miles on the
bike. Furthermore, by the time you have done this work only the engineers will
know your bike better!
Loc-tite (blue 243) and Re-Torque:
- Fender bolts
- Pipe bolts
- Side panel bolts
- All 6mm fasteners (10 Nm)
- Exhaust flange bolts
- Gas tank bolts (under seat)
- Sprocket bolts (if problematic switch to Talon or Honda CR nuts) (35 Nm)
- Kick-starter bolt (25 Nm)
- Shifter bolt (10 Nm)
- Sub-frame bolts
- Kickstand bolt
- Motor mount (45 Nm)
- Shock clamp bolts
- Carb bolts
- Seat bolts
- Shock bolts (possibly safety wire) (60 Nm)
- Rear shock set screw (Note: over-torquing can crack the ring) (6 Nm)
Torque Values for Reference:
- 6mm screws (10 Nm)
- 8mm screws (25 Nm)
- 10mm screws (45 Nm)
- 6mm nuts (15 Nm)
- 8mm nuts (30 Nm)
- 10mm nuts (50 Nm)
- Oil banjo bolts (10 Nm)
- Spokes (5-7 Nm)
- Chain adjuster bolt (every tire removal)
- Take the rear axle apart and grease it liberally as the bolt will
weld itself to the swing-arm very quickly
- Remove and re-grease all bearings, including wheel, steering head, swing
arm, chain rollers and brake pedal pivot.
Cooling System Work:
- Drain system (see manual).
- If not done already, remove the 2 (or 3?) compression clamps on the
thermostat hoses and replace with KTM hose clamps (other hose clamps
are wider and have a fatter screw head making them a pain to deal with).
- Cut down right side hose that hits the radiator. Cut it off at the
top of the hose at the last bend.
- Cut down left side radiator hose that touches radiator. Cut off about
a 1/2 inch (case side)
- Cut down the small hose that goes through the frame and connects to
both radiators at the top. (cut to fit)
- Refill System: Recommend a coolant mixture of 60-70% distilled water
and 40-30% Prestone Dex (silicate free) with Water Wetter (see manual
for further specifics). Should handle most extreme heat conditions.
If more cooling is needed KTM sells a fan setup for about $96.00.
- Bleed system as per owner's manual.
4Strokes.com Technical: KTM