Enduro bike maintenance: checklist by engine hours

Here is the enduro maintenance checklist sorted by engine-hour threshold. Keep it within reach — this is what we actually do in the workshop.

01Every 5 hours

• Air filter: clean the foam and re-oil it (Twin Air, No-Toil).
• General check: frame fasteners, footpegs, handlebar, levers.
• Tyre pressure: adjust for the terrain (see our dedicated article).
• Chain tension: around 25-35 mm of free play at the tightest point.
• Coolant level (visual, via the expansion tank).
• Engine oil level (sight glass or dipstick depending on the model).

02Every 15 hours

Everything above, plus:

• 4-stroke engine oil: full oil change plus a new oil filter.
• Spark plug: visual check, replace if fouled (every 30 h as a routine).
• 4-stroke valve clearance check: measure with a feeler gauge, shim if needed.
• Spoke tension: go round with the spoke wrench, retension anything that has moved.
• Brake pad condition: visual check on remaining thickness.

03Every 30 hours

Everything above, plus:

• Chain / sprockets: if stretch exceeds 1.5%, replace the full set (chain + rear sprocket + front sprocket).
• Fork: oil change and internal clean. Workshop job unless you have the kit.
• Pads: replace front and rear as a matter of course on a competition motocrosser.
• Tyres: replace if the carcass is damaged or the knobs are shaved.

04Every 60 hours

Everything above, plus:

• Shock: oil change and spring re-rate if needed. Suspension shop.
• Wheel bearings: check for play, replace if you can feel axial movement.
• Brake fluid: full DOT 4 bleed.
• 2-stroke 250/300 top end: on competition use. Trail riding, stretch it to 80 h max.

05Every 100 hours

Everything above, plus:

• 4-stroke 500+ enduro top end: piston and rings, inspect the cylinder.
• Steering head bearings: grease or replace if there is play.
• Clutch: replace the friction plates if it slips under load.
• Coolant: full change.
• Swingarm bearings: strip and grease.

06What depends on the terrain

• Mud / sand: halve the intervals on consumables (chain, pads, tyres, air filter).
• Dry desert: clean the air filter every 2-3 h.
• Wet forest: grease more often (bearings, linkages).

07Never miss a threshold again

With an hour meter tied to a maintenance app, every threshold triggers a notification as you cross it. You stop memorising anything — the app does the work.

On HOROTAG RUUVI, the 8 templates by engine size handle the standard thresholds automatically. You can adjust them to suit your use (competition vs trail riding, terrain).