So we have these new bikes that we have been racing this year: KTM 2007 125SX and 144SX. We have not done much to them other than oil changes and air filter cleaning to date. We have a long break in the racing so I figured it is a good time to dig into these bikes and see how they are doing.

I pulled all the wheels off to clean the seals and re-grease. While I am in there I am checking the bearings and axles out close. The rear seals are a bit dry and dirty. That is a simple fix, just clean and apply grease. Also, I pulled the axles and spacers giving them a good cleaning and greasing. The front wheel on my 144 had moisture inside that was easily cleaned out. The chains were taken off and soaked in an oil bath. We apply chain lube at every use but a dip in oil can't hurt.

For the first time in my life I have a new bike. What a treat it is to take something apart and it is not already beat to hell. Now I am wondering what other items I should be digging into to provide some lovin. At the moment I am thinking of pulling the flywheel covers and checking for any water, lubing throttle cables, and bleeding the brakes. Both bikes are due for new rear tires. The Bridgestone M70 tires that came with the bike have held up very well but they have chunks missing now and I was regretting the fact that I pushed it one more race on that chunked tire because I was missing tracktion at Swamp Creek.

So far my 144 has performed flawlessly without one single issue. Austin's 125 broke a throttle cable and his shifter fell off. The shifter was our fault, we should have put loctite on the bolt. You can be sure both bikes have loctite now. The throttle cable was a fluke. These are proving to be great bikes!

Back out in the garage,
Joe............

Remove and repack wheel bearings. If this was not done when new you REALLY need to do it now. Steering stem too..VERY important as moisture can get in there and cause big problems with that lower bearing. Swing arm bearing too....are you getting what I am layin down....ALL bearings need to be repacked with good grease. From the factory there is not enough grease and who knows how good it is.

Repack mufflers

Lube shock ball joints

Flush brake fluid...just crack the bleeder and keep filling the resevior tell the fluid runs clean.

Check all wire connections and routing to make sure nothing is loose or getting pinched.

Remove, lube with never sieze and replace chain adjust bolts.

Clean fork scraper and seal area. Wipe some seal grease on the fork tube near the seal and compress fork. It will go into the seal.

Check all motor mount, sprocket, brake disc and CS sprocket bolts.

Pull calipers from carriers and lube pins.

Pull levers from perch, clean and lube.

Loctite those kick start bolts too.

Power valve??

Sure I am missing a few things but you get the idea.

PS O-ring chains will not accept lube past the o-ring..dirt sand or anything else by design. Lubing prevents external rust and can be achieved with WD 40 type product. Disregard this comment if you have non o-ring chain and lube the crap out of it.

wow, my list of work just got longer but I have plenty of time to do it. The wheel bearings are sealed. Is there anything that can be done to sealed bearings? I've always just replaced them. These bikes have the non-oring chains and they sure do turn nice. The o-ring chains add a lot of drag. Great list of maint items, thanks.
Joe........

Small flat blade screw driver or knife will slide under the inside lip of the seal....be careful not to damage the lip. Push it under the metal (or fiber) part of the seal and pop the outer lip from the groove in the outer bearing race. If the bearing is clean inside just add grease and push seal back in place by hand.

A trick to pack a bearing is put some grease in the palm of your hand and drag the open side of the bearing through the grease and force it against your palm. Done correctly it will load the bearing complete. First time you ride it will purge some but that's OK.

Put the r & r seal side of the bearing facing "in" in the hub in case it does not seal as good as it once did.

Do this to all bearings when new and they will last a long time. Bearing companys make money selling bearings....not grease. They are never loaded with high quality grease.

If you want I can swing by and show you but it will cost you a beer....maybe 2

dlharte wrote:

If you want I can swing by and show you but it will cost you a beer....maybe 2

Wait!........................................I'll help! Beer sounds good!
J-boat

A 6 pack of corona if you come to Medford and help me. I need to do my fork seals.

I am in no hurry at all;)
Joe.......