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ENGLISH

17

Starting the engine with the kickstarter 

Be sure to kick up the side or center stand before you start the
engine to avoid any damage.Start as described above, then
push the kickstarter hard all the way.

WARNING

– I

F YOU WANT TO START THE ENGINE

MAKE SURE THAT YOU ALWAYS

PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

.

Y

OU MIGHT SLIP OFF THE KICKSTARTER

OR THE ENGINE MAY KICK

BACK THE

K

ICKSTARTER

.

– A

LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING

THE THROTTLE

. K

ICKING THE KICKSTARTER WITH NOT ENOUGH

MOMENTUM

AND AN OPENED THROTTLE GRIP INCREASE THE KICK

-

BACK HAZARD

.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly
release the clutch lever and open throttle at the same time.

WARNING

B

EFORE YOU START OFF

CHECK THAT THE CENTER STAND HAS BEEN

SWUNG RIGHT UP TO THE TOP

. I

F THE STAND DRAGS ON THE GROUND

,

THE MOTORCYCLE CAN GO OUT OF CONTROL

.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption. 
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again. If the engine is killed f.ex. at a crossing, simply
pull the clutch lever and start. It is not necessary to switch the
gear to NEUTRAL.

WARNING

– A

VOID ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY

ROADS

. O

THERWISE

THE MOTORCYCLE COULD EASILY GET OUT OF

CONTROL

.

– N

EVER TURN THE IGNITION KEY TO POSITION

OR

WHILE THE

MOTORCYCLE IS MOVING

– D

O NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING

. Y

OUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE
YOU TO LOSE CONTROL OF YOUR MOTORCYCLE

– A

FTER FALLING WITH THE MOTORCYCLE

CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

!

CAUTION

!

– H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. W

E RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP

. A

FTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

.

– S

HIFT TO THE NEXT HIGHER GEAR BY

8500 

RPM AT THE LATEST

.

– N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A

LOWER GEAR

. T

HE ENGINE WILL OVERSPEED

DAMAGING THE VALVES

.

I

N ADDITION

THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

.

– I

F THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE

YOU ARE DRIVING

THIS INDICATES COOLING SYSTEM TROUBLE

. I

MME

-

DIATELY STOP AND TURN OFF THE ENGINE

. D

RIVING WITH THE WAR

-

NING LAMP ON WILL CAUSE ENGINE DAMAGE

.

– P

LACE A CLOTH ON THE RADIATOR CAP

. O

PEN THE CAP SLOWLY

,

SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE

.

CAUTION SCALDING HAZARD! - 

AND CHECK THE COOLING

LIQUID LEVEL

.

– D

O NOT DRIVE ON

UNTIL THERE IS SUFFICIENT LIQUID IN THE COO

-

LING SYSTEM

. H

OWEVER

CALL ON ONE OF

KTM’

S DEALERS AS

SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED

– I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING

CHECK THAT

THE ENGINE FASTENING SCREWS ARE TIGHT

.

– I

N THE EVENT THAT

WHILE RIDING YOUR MOTORCYCLE

YOU NOTICE

ANY UNUSUAL OPERATION

-

RELATED NOISE

STOP IMMEDIATELY

TURN

THE ENGINE OFF

AND CONTACT AN AUTHORIZED

KTM 

DEALER

.

Braking

Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving downhill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

– D

ELAYED BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS

DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE

.

I

N THIS CASE

REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY

.

– D

ELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY

ROADS

. I

N THIS CASE

REPEATEDLY APPLY THE BRAKES TO REMOVE THE

DIRT

.

– W

HEN YOU BRAKE

THE BRAKE DISCS

BRAKE PADS

BRAKE CALIPER

AND BRAKE FLUID HEAT UP

. T

HE HOTTER THESE PARTS GET

THE WEA

-

KER THE BRAKING EFFECT

. I

N EXTREME CASES

THE ENTIRE BRAKING

SYSTEM CAN FAIL

.

– D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

.

Содержание 640 LC4 Adventure 2002

Страница 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art Nr 3 210 57 9 2002 640 LC4 ADVENTURE...

Страница 2: ...moval or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise...

Страница 3: ...and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM sh...

Страница 4: ...hedule must be performed and service records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specif...

Страница 5: ...nsion 25 Correct chain tension 25 Page Chain maintenance 26 Chain wear 26 General information about KTM disc brakes 27 Adjusting of free travel at the hand brake lever 28 Checking of brake fluid level...

Страница 6: ...e original position of the clutch lever see maintenance work on chassis and engine Hand decompression lever The hand decompression lever 2 is only used in two special cases a When the engine stalled I...

Страница 7: ...es a rich fuel air mixture necessary for cold start If the choke lever is pushed forward up to the stop the bore will be closed again In this posi tion the choke cable must have a play of approx 2 mm...

Страница 8: ...ze the CLOCK display by the blinking dots between the hours and minutes It displays the speed temperature of the cooling liquid and the clock To switch to the next display mode press the MODE button O...

Страница 9: ...TRIP 1 mode and press the SET button RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999 9 It can be used similarly to TRIP 1 or together with a switch available as an accessory...

Страница 10: ...WHEN DRIVING SLOWLY Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on NOTE The indicator lamp will blink slower when a blinker is broken The gr...

Страница 11: ...d should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position ignition circu...

Страница 12: ...urn the twist grip back to the ON position so that you will have backup fuel next time too NOTE The fuel tap must be open during operation The fuel tap must be closed for parking Shift lever The shift...

Страница 13: ...adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding BASIC SETTING turn rotary knob clockwise as far as it will go turn it back counter cl...

Страница 14: ...ENGLISH 13...

Страница 15: ...Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet Pay attention to running in instructions Running in Even finely machined surfaces of engi...

Страница 16: ...d in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum v...

Страница 17: ...Check if the ignition is on the headlight is on If this is not the case the battery is discharged If the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer IF...

Страница 18: ...THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN...

Страница 19: ...YCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS NOTE REGARDING THE CENTER STAND We advice the following procedure to place the motorcycle on the center stand as effortlessly as possible a press...

Страница 20: ...ENGLISH 19...

Страница 21: ...p flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws and nuts are tight Check brake fluid level lining thickness and brake...

Страница 22: ...ricate chain as necessary Check chain tension Clean air filter and filter box depending on the dirt accumulation Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float...

Страница 23: ...OPERLY DISPOSE OF OIL GREASE FILTERS FUEL CLEANSERS BRAKE FLUID COOLING LIQUID ETC OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY ALSO OBSERVE THE SAFETY REGULATIONS WHEN HANDLING THESE SUBSTANCES...

Страница 24: ...00 Bleeder screw front fork The bleeder screws 3 should now and then be released a few turns to let overpressure if any escape from the interior of the fork To do this place the motorcycle on a stand...

Страница 25: ...ted on the rear shock absorber serves as a vibration damper This ring gets pressed together with time and loses its shock absorbing quality Measure the distance between the two discs at various points...

Страница 26: ...OULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen counter nuts 2 and turn rig...

Страница 27: ...T THE CLOSED SIDE OF THE SAFETY DEVICE MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear In order to check the chain wear regard the fo...

Страница 28: ...CYCLE WILL NOT LON GER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rea...

Страница 29: ...rvoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with brake fluid DOT 4 Motorex...

Страница 30: ...uid reservoir it is recommended to remove the hexagon screw 3 Then move the container outwards as indicated in the illustration Remove plug 4 with rubber boot 5 and add brake fluid DOT 4 Motorex Brake...

Страница 31: ...LE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY...

Страница 32: ...DURO 4 KAROO MICHELIN SIRAC T63 PIRELLI MT21 MT60 MT70 MT90 Tire type and size can be found in the technical specifications and in the homologation certificate Tire condition has to be checked every t...

Страница 33: ...ealer WARNING SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPO...

Страница 34: ...HE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temper...

Страница 35: ...THE WHOLE ELECTRICAL INSTALLATION Removing and mounting the headlight mask The headlight mask must be removed to replace the headlight lamps the indicator lamps or the tachometer lamps REMOVING THE HE...

Страница 36: ...the fuel lines to the 3 fuel cocks Unplug the plug connector 3 to the gasoline level sensor CAUTION THE GASOLINE LEVEL SENSOR WILL BE DAMAGED IF THE PLUG CONNECTOR 3 IS NOT UNPLUGGED WHEN YOU REMOVE T...

Страница 37: ...in the cooling system Go to your nearest KTM garage and get it seen to If you drive with the cooling liquid temperature warning light on you will cause even more damages to the engine The cooling fan...

Страница 38: ...d allow the filter to dry Lubricate the dry air filter thoroughly with high grade filter oil rubbing to coat the entire filter surface Clean the filter box and cover and check the carburetor connectio...

Страница 39: ...e oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraul...

Страница 40: ...lowly operate the kickstarter through its stroke until the clicking sound disengaging of the automatic decompression can be heard Now the decompression lever must be operated 10 mm 0 39 in until resis...

Страница 41: ...EAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY Engine oil On...

Страница 42: ...ailure Therefore we recommend that you have the engine oil changed by your authorized KTM mechanic During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise t...

Страница 43: ...turn off the engine and mount the plug together with the gasket Allow the engine to warm up check the engine oil level and correct if neces sary Afterwards check the entire oil system for leakage Mou...

Страница 44: ...ntact a KTM dealer Replace fuse 3 Remove seat and replace the main fuse 1 If fuse blows again contact a KTM dealer Recharge the battery and investigate the causes for dischar ging contact a KTM dealer...

Страница 45: ...blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created exchange the spark plug If the new spark plug doesn t produce a spark either dis con...

Страница 46: ...id use antifreezer with brand name Shorten or replace cooling hose Remove and check thermostat opening temperature 70 C 158 F or replace it contact a KTM dealer Replace fuse and check if fan operates...

Страница 47: ...e opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the k...

Страница 48: ...ENGLISH 47...

Страница 49: ...hain Camshaft 584 V03 1 Valve diameter Intake 36 mm Exhaust 30 mm Valve clearence cold Intake 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearin...

Страница 50: ...head top sect M6x50 M6x55 12 9 15 Nm 11ft lb Cylinder head screws M10 50 Nm 37ft lb Collar nuts at cylinder base M10 40 Nm 30ft lb Hexagon screw chain sprocket M10 10 9 Loctite 243 60 Nm 44ft lb Oil d...

Страница 51: ...liter 0 9 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Lampenbest ckung head light H1 12V 55W Sockel P14 5S parking light 12V 2W Sockel Ba9s brake rear light 12V 21 5W Sockel BaY1...

Страница 52: ...100 Nm 74ft lb Engine mounting screw M10 45 Nm 33ft lb Sprocket screws on nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swingarm bolt M14x1 5 100 Nm 74ft lb Clamping screws top triple clamp MXMA 4860 M...

Страница 53: ...Page Correct chain tension 25 Chain maintenance 26 Chain wear 26 General information about KTM disc brakes 27 Adjusting of free travel at the hand brake lever 28 Checking of brake fluid level front br...

Страница 54: ...ANHANG APPENDICE APPENDIX AP NDICE 1...

Страница 55: ...OF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpo...

Страница 56: ...breather never exceed top mark at operating temperature IMPORTANT Before you go for the first ride on your motorbike read the entire User s Guide carefully WARNING THIS SHOCK ABSORBER CON TAINS NITROG...

Страница 57: ...ANHANG APPENDICE APPENDIX AP NDICE 4...

Страница 58: ...ANHANG APPENDICE APPENDIX AP NDICE 5...

Страница 59: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321057...

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