Most KTM and KTM Group two-stroke engines share a similar oil change process. They all use a magnetic 13mm drain bolt and an oil level bolt to ensure correct fill levels. Follow these steps next time you service your bike and change the gearbox oil to keep things running smooth.

#1 STAND IT UP

Place the motorcycle on a sturdy workbench or stand so the bottom of the engine is easy to access.

#2 LOCATE THE PLUG
Find the sump plug. It’s usually on the lower left side of the engine, but some models have it on the right.

#3 DRAIN IT
Remove the sump plug and let the oil drain completely into a catch tray.

#4 CLEAN THE PLUG
While the oil is draining, clean the magnetic sump plug using parts cleaner and blow it off with compressed air.

#5 REMOVE CAPS
Remove the filler cap and the oil level bolt. The oil level bolt is an 8mm bolt with a copper washer, usually on the side of the engine – either in the clutch cover, inner clutch cover, or, on smaller models like the 50 and 65cc, on the left side of the engine.

#6 REFIT SUMP PLUG
Once drained, refit the sump plug – don’t forget to reinstall the copper sealing washer.

#7 FILL IT SLOWLY
Pour in new gearbox oil slowly until it just starts to drip from the level bolt hole.

#8 REFIT BOLTS
Once oil stops dripping from the level hole, refit the level bolt and tighten the filler cap.

#9 CLEAN UP
Wipe down any oil residue using parts cleaner and a rag before firing the bike up and heading out for a ride.

 

DOS

– Replace any damaged or worn copper washers
– Fill the oil slowly to avoid overfilling
– Tighten sump and level bolts to manufacturer specs

DON’TS

– Over-tighten bolts or plugs
– Reuse damaged washers
– Overfill the engine

 

TOOLS

Spanners, T-bars, oil, drain tray, rags, parts cleaner

 

WARNING

Failing to follow this procedure properly can result in serious engine damage or failure.

 

HOW OFTEN SHOULD YOU DO IT?

KTM recommends changing the gearbox oil every 2-8 hours, depending on riding style and terrain. If you’re heavy on the clutch or riding in tough conditions, you’ll need to change it more frequently. Lighter use = longer intervals. Stick to a regular schedule to maximise engine life.