KTM LC4 400-660LC42003 engine. Manual - part 35

11-5D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil







Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point



Drain and clean carburetor float chamber







Adjust idling



Check breather hoses of engine gase and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Maintain chain tension eccentrics



Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber of telescopic fork





Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber





Check O-ring of the shock absorber for wear 





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 2500 km  

(1500 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING

OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE

NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

DUKE-E  2.98

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

11-6D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil



Change oil filter unit







Change microfilter





Check oil lines for leakage and proper instalment





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)

Check valve clearance



Drain and clean carburetor float bowl







Adjust idling



Check breather hoses of engine gase and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreeze



Check cooling system for leaks







Check exhaust system for leakage



Change exhaust muffler packing (aluminium-muffler)





Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)

Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check freeplay and easy operation of hand brake lever and foot brake lever







Check adjustment and function of fork





Check fork for leaks



Loosen breather screws at fork legs (overpressure)



Change fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber on forks







Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and function of shock absorber





Check O-ring of the shock absorber for wear





Servicing the shock absorber



Grease lubricating nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system and perform a full maintenance job on it



Servicing swingarm pivots



Check tightness of spokes and rim join







Check wheel bearings for clearance





Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check adjustment of head light



Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding components







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after  1000 km (600 miles) or 10 hours

after 2500 km   (1500 miles) or 25 hours

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD 

RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) 

SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

2.99

620 SX

400/540 SXC

400/620 SC

11-7D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil



Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)

Drain and clean carburetor float chamber







Adjust idling



Check all air supply and ventilation hoses of the engine and of the carburetor for kinks.





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)

Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Loosen bleeder screws at fork legs (overpressure)



Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber of telescopic fork





Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and function of shock absorber





Check O-ring of the shock absorber for wear





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD 

RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) 

SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

400/640 LC4 ’99

400/640 LC4 

R

’99

620 LC4 Comp.’99

620/640 Supermoto ‘99

10. 98

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

11-8D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil



Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point



Drain and clean carburetor float chamber







Adjust idling



Check breather hoses of engine case and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Loosen bleeder screws at fork legs (overpressure)



Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber of telescopic fork





Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and function of shock absorber





Check O-ring of the shock absorber for wear





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD 

RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) 

SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

Adventure  09.98

11-9D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil



Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)

Drain and clean carburetor float chamber







Adjust idling



Check breather hoses of engine gase and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Maintain chain tension eccentrics



Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Clean spark arrestor discs (USA model)



Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check wear of brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Loosen breather screws at fork legs (overpressure)





Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber





Check O-ring of the shock absorber for wear 





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM 

(3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE

Duke  5.99

11-10D

PERIODIC MAINTENANCE SCHEDULE

after / every

2500 km

or

25 hours

1. Service after

1000 km

or

10 hours

after / every

5000 km

or

once a year

IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

S

ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN

5 

HOURS OR

500 

KM

.

M

AINTENANCE WORK DONE BY

KTM 

AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER

!

A washed motorcycle can be checked more quickly which saves money!

Change engine oil, oil filter, and micro-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 bolts for tight fit

●

●

Check carburetor connection boots for cracks and leaks

●

Check idle setting

●

●

Check bleeder hoses for damage and kink-free arrangement

●

●

Check cooling system for leaks, antifreeze protection

●

●

Check exhaust system for leaks and suspension

●

●

Check actuating cables for damage, smooth operation, and kink-less

●

●

arrangement, adjust and lubricate
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,

●

●

tell-tale lamps, speedometer illumination, horn, emergency-off switch)
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 bolts of brake system for tight fit

●

●

Check suspension strut and fork for leaks and proper function

●

●

Check O-ring of suspension strut for wear

●

Clean dust sleeves

●

Bleed fork legs

●

●

Check swinging-fork pivot

●

Check/adjust steering-head bearing

●

●

Lubricate reversing lever

●

Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,

●

●

swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join

●

●

Check tire condition and inflation pressure

●

●

Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension

●

●

Lubricate chain

●

●

Check wheel bearings and jerk damper for play

●

IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER

Perform complete fork maintenance

●

Perform complete suspension strut maintenance

●

Perform complete reversing lever maintenance

●

Replace glass-fiber yarn packing of main silencer

●

Clean and lubricate steering-head bearing and sealing elements

●

Clean and adjust the carburetor

●

Treat the electrical contacts and switches with contact spray

●

Change brake fluid

●

WHEELS

CHASSIS

BRAKES

ADD-ON-P

AR

TS

CARBURA

TOR

ENGINE

620 SC

every 2 years

or 20000 km

at least

once a year

every 2500 km

or 25 hours

11-11D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

Check oil level

●

Check brake fluid level

●

Check brake pads for wear

●

Check lighting system for proper operation

●

Check horn for proper operation

●

Lubricate and adjust actuating cables and nipples

●

Bleed fork legs in regular intervals

●

Remove and clean dust sleeves in regular intervals 

●

Clean and lubricate chain as necessary

●

●

Check chain tension

●

●

Clean air filter and filter box

●

Check tire pressure and wear

●

Check coolant level

●

Check fuel lines for leaks

●

Drain float chamber

●

Verify smooth operation of all controls

●

Check brake performance

●

●

Btreat exposed metal components (except for the braking and exhaust 

●

systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray

●

Check all bolts, nuts, and hose clamps for their tight fit

●

once a year

for cross

country use

after every

cleaning

before each

start

11-12D

PERIODIC MAINTENANCE SCHEDULE

1. Service

after

1000 km

2. Service after
5000 km, then

every 5000 km or

once a year

IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

S

ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN

500 

KM

.

M

AINTENANCE WORK DONE BY

KTM 

AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER

!

A washed motorcycle can be checked more quickly which saves money!

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 bolts for tight fit

●

●

Check carburetor connection boots for cracks and leaks

●

Check idle setting

●

●

Check bleeder hoses for damage and kink-free arrangement

●

●

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, 

●

●

and adjust and lubricate them
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)
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 bolts of brake system for tight fit

●

●

Check suspension strut and fork for leaks and proper operation

●

●

Check O-ring of suspension strut for wear

●

Clean dust sleeves

●

Bleed fork legs

●

●

Check swinging-fork pivot

●

●

Check/adjust steering-head bearing

●

●

Lubricate reversing lever

●

Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, 

●

●

swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join

●

●

Check tire condition and inflation pressure

●

●

Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension

●

●

Lubricate chain

●

●

Check wheel bearings and jerk damper for play

●

IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER

Perform complete fork maintenance

●

Perform complete suspension strut maintenance

●

Perform complete reversing lever maintenance

●

Clean and lubricate steering-head bearing and sealing elements

●

Clean and adjust the carburetor

●

Treat the electrical contacts and switches with contact spray

●

Treat battery connections with contact grease

●

Change the brake fluid

●

WHEELS

CHASSIS

BRAKES

ADD-ON-P

AR

TS

CARBURETOR

ENGINE

400/640 LC4-E

640 LC4 Adventure

every 2 years

or 20000 km

at least

once a year