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Old 07-14-2010, 10:44 AM   #1
nwaneal OP
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Location: Fayetteville, AR
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KTM 450 EXC Maintenance

Hey Crew,

I just bought a 2004 KTM 450 EXC. The first thing I do with used bikes is do a complete maintenance check. Oil, filters, air filter, coolant, grease everything, Valve check, etc.

What are some maintenance requirements for these bikes? The bike will be ridden hard off-road and eventually dual sported and sumo'd.

Oil Change interval?
The manual says Motorex 10w50. Royal Purple 10w40 came highly recommended.

Oil Filter Interval?
Any better aftermarket filters for a lower price?

Long and Short Screen cleaning interval?
I had originally planned to clean every oil change.

Valve Adjustments?
How often should I be checking? What are signs that the valves may need adjusted?

Any shortcuts or cost saving tips? I know these bikes are pretty maintenance heavy.

I am in Dallas, TX if that makes a difference.

Thanks for the help and let me know of any issues I might encounter during ownership.
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Old 07-14-2010, 12:07 PM   #2
Albie
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I change my oil about every 1K miles. Usually check the valves every other oil change, clean the screens every oil change and change filters every other. Oil is a touchy subject so I'll just say use what you like LOL. I clean the air filter or replace it as needed.

I use both OEM oil filters and Hi Flo (supposedly they make the KTM filters). The Hi Flo's are usually a great deal.
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Old 07-14-2010, 12:24 PM   #3
Lumpyboy
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Actually, the RFS motor is pretty easy maintenance wise. The newer XC4 motor has more intensive maintenance (not that it is hard). Regardless of motor, I usually change oil every 5-10 hours on my 400/450 bikes (pretty conservative though) and change the filters/clean screens every second or third oil change. Agree with Albie that any good oil will be fine as the RFS motors are not picky.
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Old 07-14-2010, 02:16 PM   #4
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Air filter every ride, and make sure it is seated correctly. Can't stress that enough. Dirt in the intake and soft valves are your only worries.

Adjust the Intake/exhaust valves with a 3/1 ratio. The exhausts never move.
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Old 07-14-2010, 02:23 PM   #5
zenjen
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owner manual / parts fiche

If your bike did not come with a owners manual you can download one from the KTMUSA site.

The MUNNRACING site will have a parts fiche.

Enjoy your new bike.
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Old 07-14-2010, 02:34 PM   #6
SnowMule
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Not the same bike, i've got teh 525XC-W... still the same RFS with the same issues.

Oil changes I do every 15hrs. Rotella T6 hasn't given me any problems and it's <$20/gallon.

Valve changes I've been doing every other oil change, they don't move all that much... probably go every 3rd oil change. Tip: 1/6 of a turn on the screw is the .005" spec. The lock nut has six sides. I loosen the lock nut, run the screw up/down a few times, then get it seated on the valve and back it off 1/6 of a turn (one corner on the nut) and lock it down. When I check them with feeler gauges they're dead on using this method, I don't bother fighting those damn feeler gauges anymore.

+1 for keeping the air filter clean/seated.

There's a few bolts that like to loosen up and come off. The two on the lower part of the subframe (near the rear brake cyl), the big fender screw on the front fender, kickstand, and shifter are the ones I make sure to check/tighten the most often.

Nice bikes. Real nice bikes.
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Old 07-14-2010, 03:28 PM   #7
Skowinski
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Joined: Nov 2009
Location: Mojave Desert
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I go by mileage.

Oil changes every ~200 miles. Filters/screens every other oil change.

Valve adjustments every ~500-600 miles.

Oil? Any good oil will do, I use either semi-synthetic or full synthetic motorcycle oil, depends on what is there in the garage at the time. Most important thing is to keep clean oil in it. I probably overdo the oil changes, but for me I'd rather err on the side of caution.

Air filter checked after every ride and cleaned if dirty.

The 05 I have now is my second RFS. Fantastic bikes. Love the power.
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Old 07-16-2010, 08:42 AM   #8
jgbnm
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I have an 06 400 EXC ridden hard and off-road only. 3300 miles and hosed down occasionally.

- oil changes every 2-3 rides and generally < 200 miles).
- always Rotella 5w40 synthetic since day one - cheap and good oil.
- oil filters every 2-3 oil changes (10 pack of filters - 5 of each at Procycle for $40 + shipping). HiFlo (Hi Flo?) filters are what most people seem to use. Can also find packs of them on Ebay.
- oil screens every once in a while... maybe every 2-3 filter changes
- check valves about 2x/year or when I notice the bike getting a bit harder to start (main symptom). Intakes tend to get tight more than exhausts. No shims, so it's easy. Motion pro feeler gauge highly recommended for easiest access.

RFS engines are very reliable.
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Old 07-16-2010, 08:45 AM   #9
jgbnm
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Air filter changed when dirty. 1-3 rides generally. Never seen any sign of any dust getting past. It's a nice design that seals well and has easy access. I rotate through 3 air filters as it's a pain to clean just one at at time.
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Old 07-22-2010, 01:17 PM   #10
nwaneal OP
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Look sliek I am going to have to put a radiator fan kit on the bike as well. It was spewing coolant last weekend on the slow trails. Any advice?
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Old 07-22-2010, 01:35 PM   #11
cagiva549
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Coolant overflow recovery system , I made mine after one ride and havent added water since . I do have a new fan kit in the box if you want it I will part with it for a $100 bucks , I only ride in the winter so I dont need it . SEYA
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Old 07-22-2010, 01:40 PM   #12
fullmonte
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Quote:
Originally Posted by nwaneal
Look sliek I am going to have to put a radiator fan kit on the bike as well. It was spewing coolant last weekend on the slow trails. Any advice?
Ride faster and keep a bottle of Engine Ice in your pack. Found that out the hard way too.
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Old 07-22-2010, 01:57 PM   #13
nwaneal OP
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Coolant recovery Kit

How do you make one of these?
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Old 07-22-2010, 02:33 PM   #14
ThumperDRZ
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Quote:
Originally Posted by nwaneal
How do you make one of these?
How about a nice kit...

http://www.rlrproducts.com/
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Old 07-22-2010, 03:31 PM   #15
LukasM
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Quote:
Originally Posted by ThumperDRZ
How about a nice kit...

http://www.rlrproducts.com/
+1.

Very well thought out kit for the EXC and it's so cheap that I wouldn't bother looking for the small parts yourself - even though you could get the tank from a hobby shop, it's an RC plane/heli/car fuel tank, then the fittings, the hose, etc.

The owner Randy is a really nice guy, too.
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