KTM RF4 Engine Maintenance : ktm-parts.com Customer Support

Forums/Tips & Tricks

KTM RF4 Engine Maintenance

Jamin
posted this on January 12, 2011 11:10

TB0920R RF4 Engine Maintenance

KTM TECHNICAL BULLETIN TB 0920R

SEPTEMBER 4 » 2009

Subject: KTM RF4 Engine Maintenance Guidelines

Affected Models: 2007 - 2009 450 / 505 SX-F and 450 / 505 XC-F, 2009 450 / 505 SX ATV

Initial Information:

» The following information in addition to the Periodic Maintenance Schedule for the above mentioned models, will ensure that the RF4 engine is maintained in the best possible manner. Always refer to the owner’s manual or shop manual for correct procedures and specifications. This bulletin is not a warranty item.

Engine	Operating Hours Intervals	Ea. Race Weekend / 3 H	10 H	20 H	40 H
	Oil & Filter change
	Measure bypass spring length
	Replace Piston CPL.
	Measure Clutch Plates for wear
	Replace Intake & Exhaust Valves
	Measure PSI Pump axial clearance

Oil Pressure Pump:

» During the course of the first service interval at 3 hours of operation, it is recommended to check/adjust the axial clearance of the oil pump (pressure side) to maintain optimal oil pressure.

» Measure the width of the pump rotors, measure the depth of the pump cover, then subtract the rotor width from cover depth. The result should be a clearance between 0.01 – 0.03mm. If the clearance is greater than 0.03mm, lightly surface the cover with 1200 grit sand paper on a flat surface until the proper clearance is achieved.

» After inspection of the oil pressure bypass spring, we recommend to verify oil pressure as described in the repair manual. If the oil pressure does not meet the specified amount and the pressure pump is adjusted as previously described, we recommend that the oil filter be replaced with a new one, and also the oil filter screen be cleaned or replaced.

» If oil pressure is still below the specification, it is recommended to add a 1mm preload washer “p.n.0988060121” to the oil pressure bypass spring (8mm AH plug screw side) to increase oil pressure during spring inspection.

The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected property. Alteration, assignment, distribution and reproduction are forbidden.

LIMITATION OF LIABILITY

The information included in or available through this technical information may include inaccuracies or errors. In no event shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Technical Service Department.