KTM 640 LC4 Adventure 2002 Скачать руководство пользователя

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ENGLISH

15 t
16 t for chain
17 t

38 t
40 t for chain
42 t

45 t
48 t

31:79

Primary

ratio

Transmission

Available chain
drive sprockets

Available final

drive sprockets

GEAR RATIOS

1st gear

14:35

2nd gear 15:24
3rd gear

18:21

4th gear

20:19

5th gear

22:18

Original final

drive ratio

15:45
16:42
17:38
17:42

–

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API: SG, SH

TEMPERATURE

Engine oil

Use only synthetic oil brands, which meet quality requirements (Motorex
Powers Synt 4T) of API-classes SG or SH (informations on bottles) or higher.

CAUTION

OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE

WEAR

TECHNICAL DATA – ENGINE 640 LC4 ADVENTURE 2003

Type

640 LC4

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter

Displacement

625 ccm

Bore / Stroke

101 / 78 mm

Ratio

11,5 : 1

Fuel

unleaded premium gasoline with a least RON 95

Valve timing

4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain

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 bearing

Top end bearing

bronze bushing

Piston

forged/cast aluminium alloy

Piston rings

1 compression ring, 1 taper face ring, 1 oil scraper ring

Engine lubrication

2 Eaton-Oilpumps

Quantity of engine oil

see table

Engine oil

2.1 liters including frame

Primary ratio

straight geared spur wheels 31 : 79 teeth

Clutch

multi disc clutch in oil bath, hydraulically operated

Transmission

5-speed claw shifted

Ignition system

contactless DC- CDI ignition with digital advanced system type KOKUSAN

Ignition timing

adjustment to max. 38° BTDC at 6000 rpm

Generator

12V 200W

Spark plug

NGK DCPR 8 E

Spark plug gap

0.9 mm

Cooling system

liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump

Cooling liquid

at least –25° C (–13° F)

Starting equipment

electric starter, kick starter

BASIC CARBURETOR SETTING

Type

BST40-266

Main jet

152,5

Needle jet

X-6 689

Idling jet

Jet needle

6G5

Needle clip pos. f. top

3. from top

Mixt. adj. screw open

2,25

640 LC4 Adventure

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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