KTM 400-660 LC4 1998-2005, Repair Manual

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12-42F
PERIODIC MAINTENANCE SCHEDULE 2005
640 LC4 ADVENTURE 2005
A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st Service
after
1000 km
2nd Service after
5000 km, then
every 5000 km
or once a year
ENGINE
Change engine oil, oil filter, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening screws for tight fit
Make sure all engine screws accessible from the outside are screwed tight
CARBURETOR
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
ADD-ON-PARTS
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them
Check fluid level of the clutch master cylinder
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams,
stop light, turn indicators, headlamp, flasher, tell-tale lamps,
speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all screws and nuts are tight
BRAKES
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check screws of brake system for tight fit
CHASSIS
Check suspension strut and fork for leaks and proper operation
Check O-ring of suspension strut for wear
Clean fork dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,
swinging-fork pivot, reversing lever, suspension strut)
WHEELS
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension.
Check screws on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!