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

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 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