KTM 640 LC4 ENDURO 2004 Скачать руководство пользователя

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ENGLISH

Collar nut front axle

M16x1.5

40 Nm

Collar nut rear axle

M20x1.5

80 Nm

Shock absorber top

M10

45 Nm

Shock absorber bottom

M10

45 Nm

Collar screws brake disk front/rear

M6 (10.9)

Loctite 243 + 10 Nm

Screw brake caliper front (LC4)

Loctite 243 + 25 Nm

Screw brake caliper front (Supermoto)

M10

Loctite 243 + 40 Nm

Bearing bolt linkage arm/frame

M12

60 Nm

Collar nuts rocker arm bolts

M14x1.5

100 Nm

Engine mounting screw

M10

45 Nm

Ball joint for push rod

Loctite 243 + 25 Nm

Sprocket screws on nuts

Loctite 243 + 35 Nm

Hexagon nut swingarm bolt

M14x1.5

100 Nm

Clamping screws top triple clamp

20 Nm

Clamping screws bottom triple clamp

15 Nm

Clamping screws fork stubs

10 Nm

Screws handlebar clamp

Loctite 243 + 20 Nm

Allan head screw handle bar support

M10

Loctite 243 + 20 Nm

Bleeder screw oil reservoir frame

M16x1.5

25 Nm

Spoke nipple

4 Nm

Other screws on chassis

10 Nm

25 Nm

M10

45 Nm

Other collar nuts on chassis

15 Nm

30 Nm

M10

50 Nm

TIGHTENING TORQUES - CHASSIS

Содержание 640 LC4 ENDURO 2004

Страница 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 210 85 640 LC4 ENDURO 640 LC4 SUPERMOTO BEDIENUNGSANLEITUNG2004...

Страница 2: ...emoval 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 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: ...e Lubrication and Maintenance Schedule must be performed and service records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty...

Страница 5: ...ral information on KTM disc brakes 25 Adjisting of free travel at the hand brake lever 26 Changing the basic position of the handbrake lever 26 Checking of brake fluid level front brake 26 Refilling t...

Страница 6: ...d decompression lever 2 is only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the next attempt This is due to the fact th...

Страница 7: ...nize the OK 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 OD...

Страница 8: ...e 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 9: ...n idling position The blue indicator lamp will light up when the high beams are switched on The red warning lamp will start to blink when the cooling liquid reaches 120 C 248 F This warning light has...

Страница 10: ...uld 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 circuit an...

Страница 11: ...er to turn the twist grip back to the ON position so that you will have backup fuel next time too Shift lever The shift lever is mounted on the left side of the engine The position of the gears is sho...

Страница 12: ...tary knob clockwise as far as it will go turn it back counter clockwise by as many clicks as are specified for the relevant type of fork WP 0518Y737 12 Klicks 640 LC4 WP 1418Y750 15 Klicks 640 LC4 Sup...

Страница 13: ...OR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING DO NOT DRIVE AFTER...

Страница 14: ...ance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be ref...

Страница 15: ...Check if the emergency OFF switch is on 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 shoo...

Страница 16: ...N HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER T...

Страница 17: ...ADDITIONAL LOAD ONTO THE SIDE STAND YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME AND YOUR MOTORBIKE MAY FALL OVER NOTE REGARDING THE CENTER STAND is available as an accessory We advise the fol...

Страница 18: ...ENGLISH 17...

Страница 19: ...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 Check brake fluid leve...

Страница 20: ...eck 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 chamber Check all control e...

Страница 21: ...NNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OIL GREASE FILTERS FUELS CLEANING AGENTS ETC ACCORDING TO YOUR LOCAL REGULATIONS UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED...

Страница 22: ...ugs 3 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainl...

Страница 23: ...ker arm must be greased Motorex Long Therm 2000 in regular intervals For this purpose a grease nipple 3 is mounted on the rocker arm CAUTION AFTER EACH TIME THE MOTORCYCLE IS WASHED IT IS ESPECIALLY I...

Страница 24: ...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 right and left adjusting screws 3 equ...

Страница 25: ...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 26: ...MPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the...

Страница 27: ...ith the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the...

Страница 28: ...URE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED VORSICHT IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY THE STEEL COMPONENTS OF THE BRA...

Страница 29: ...screw and fix the brake fluid reservoir to the frame always making sure to prevent kinks in the connecting hose WARNING NEVER USE DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR S...

Страница 30: ...e down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp sc...

Страница 31: ...HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WH...

Страница 32: ...S IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT NEW WHEEL...

Страница 33: ...aring the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C 30 95 F Do not expose to direct sunlight Charging the battery NOTE A battery charge...

Страница 34: ...ERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Exchanging the headlight lamp Replacing the headlight bulb Remove the headlight mask Remove screw 1 on the left and right Tilt the headligh...

Страница 35: ...E NORMAL OPERATING TEMPERATURE POSSIBLE CAUSES SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE IF POSSIBLE INCREASE YOUR RUNNING SPEED SO THAT MORE AIR CAN BLOW THROUGH THE RADIATORS SHOULD T...

Страница 36: ...box cover Detach retaining clip 2 and remove the air filter 3 including the filter holder 4 from the filter box Remove the air filter from the filter holder and wash thoroughly in special cleaning flu...

Страница 37: ...ssary add SAE 10 biodegradable hydraulic oil Motorex Kupplungs fluid 75 available from your authorized KTM workshop CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER...

Страница 38: ...ew 5 accordingly Tighten counter nut and push back protective cover CAUTION IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made to the autom...

Страница 39: ...cle specifications Different technical develop ments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing...

Страница 40: ...may result in engine failure 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 K...

Страница 41: ...o the air filter box by way of the engine venting system Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING THE ENGINE OIL LEVEL...

Страница 42: ...y OFF switch contact a KTM dealer Replace fuse 3 Remove seat and replace the main fuse 1 If fuse blows again contact a KTM dealer Contact a KTM dealer Contact a KTM dealer Open fuel tap tank fuel you...

Страница 43: ...emble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Dismount carburetor and check if worn out Replace float needle Replace float Adjust choke cable...

Страница 44: ...use Main fuse melted through Defective sensor cable or oxidized socket connector REMEDY Readjust or replace ventilation hose Check engine oil level when the engine is warm correct if necessary Use thi...

Страница 45: ...tarter 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 kickstarter until you can...

Страница 46: ...gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 16 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d instrument lights LED i...

Страница 47: ...Nm Engine mounting screw M10 45 Nm Ball joint for push rod M8 Loctite 243 25 Nm Sprocket screws on nuts M8 Loctite 243 35 Nm Hexagon nut swingarm bolt M14x1 5 100 Nm Clamping screws top triple clamp M...

Страница 48: ...il bath hydraulically operated Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system t...

Страница 49: ...smounting and mounting the front wheel LC4 Supermoto 29 Dismounting and mounting the front wheel LC4 29 Dismounting and mounting the rear wheel 30 Draining the carburetor float chamber 38 Driving inst...

Страница 50: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 8 2003 FOTO MITTERBAUER...

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