| 4Strokes.com KTM Technical: KTM RFS Setup Tricks 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 a problem switch to the 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)
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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)
Check Torque:
- Oil banjo bolts (10 Nm)
- Spokes (5-7 Nm)
Anti-Seize/Grease:
- Chain adjuster bolt (at first and every time the
tire is removed)
- 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).
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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.
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