KTM LC4 400-660LC42003 engine. Manual - part 36

 

  Index      Manuals     KTM LC4 400-660LC42003 engine. Repair Manual

 

Search            

 

 

 

 

 

 

 

 

Content   ..  34  35  36  37   ..

 

 

KTM LC4 400-660LC42003 engine. Manual - part 36

 

 

11-13D

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

Treat 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

11-14D

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 function

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,

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 function

Check O-ring of suspension strut for wear

Clean dust sleeves

Bleed fork legs

Check swinging-fork pivot

Check/adjust steering-head bearing

Service eccentric for chain tension

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 tire condition, inflation pressure, and rim condition

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 the silencers

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

CARBUT

ATOR

ENGINE

640 Duke II

every 2 years

or 20000 km

at least

once a year

11-15D

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 function

Check horn for proper function

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 braking performance

Treat 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 com-

petition use

after every

cleaning

before each

start

11-16D

PERIODIC MAINTENANCE SCHEDULE 2002

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

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 every 10,000 km

Check and adjust valve clearance

Check engine fastening bolts for tight fit

Check all engine bolts accessible from the outside 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, horn)

Make sure all bolts and nuts are tight.

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 and chain guides for wear, force fit and tension.

Check bolts on pinion and chain sprocket for locking devices and a tight fit.

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

625 SC

625 SC SUPERMOTO

every 2 years

or 20000 km

at least

once a year

every 2500 km

or 25 hours

11-17D

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

Treat exposed metal components (except for the braking and exhaust 

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

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

once a year

for cross

country use

after every

cleaning

before each

start

11-18D

PERIODIC MAINTENANCE SCHEDULE 2002

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 and oil 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 all engine bolts accessible from the outside 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,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)
Make sure all bolts and nuts are tight.

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 fork 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 joint

Check tire condition and inflation pressure

Check chain and chain guides for wear, force fit and tension.

Check bolts on pinion and chain sprocket for locking devices and a tight fit.

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

640 LC4, LC4 SUPERMOTO

640 LC4 ADVENTURE

every 2 years

or 20000 km

at least

once a year

11-19D

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 fork 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

Check all control elements for smooth running

Check brake performance

Treat 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

11-20D

PERIODIC MAINTENANCE SCHEDULE 2002

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 function

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,

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 function

Check O-ring of suspension strut for wear

Clean dust sleeves

Bleed fork legs

Check swinging-fork pivot

Check/adjust steering-head bearing

Service eccentric for chain tension

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 tire condition, inflation pressure, and rim condition

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 the silencers

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

CARBUT

ATOR

ENGINE

640 Duke II

every 2 years

or 20000 km

at least

once a year

 

 

 

 

 

 

 

Content   ..  34  35  36  37   ..