KTM LC4 400-660LC42003 engine. Manual - part 37

11-21D

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

after every

cleaning

before each

start

11-22D

PERIODIC MAINTENANCE SCHEDULE 2003

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

●

●

Make sure all engine bolts accessible from the outside are screwed tight

●

●

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, 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 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 SXC

660 SMC

every 2 years

or 20000 km

at least

once a year

every 2500 km

or 25 hours

11-23D

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 (depending on the dirt accumulation)

●

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

11-24D

PERIODIC MAINTENANCE SCHEDULE 2003

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

●

●

Make sure all engine bolts accessible from the outside are screwed tight

●

●

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, 640 LC4 SUPERMOTO

640 LC4 ADVENTURE

every 2 years

or 20000 km

at least

once a year

11-25D

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 (depending on the dirt accumulation)

●

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

11-26D

PERIODIC MAINTENANCE SCHEDULE 2003

1st Service

after

1000 km

2nd 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 MORE 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 filters, 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/foot brake 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

every 2 years

or 20000 km

at least

once a year

11-27D

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

after every

cleaning

before each

start

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

MODEL1998
WIRING DIAGRAM  400 / 540 SXC  . . . . . . . . . . . . . . . . . . . . . .12-3

WIRING DIAGRAM  400 / 620 SC (For Competition)  . . . . . . . . .12-5

WIRING DIAGRAM  400 / 620 SC (For Australia)  . . . . . . . . . . . .12-7

WIRING DIAGRAM  400 / 620 SC (For Germany)  . . . . . . . . . . . .12-9

WIRING DIAGRAM  640 LC4 (For USA) . . . . . . . . . . . . . . . . . . .1211

WIRING DIAGRAM  640 ADVENTURE-R (Dell Orto)  . . . . . . . . .12-13

WIRING DIAGRAM  640 DUKE-E  . . . . . . . . . . . . . . . . . . . . . . .12-15

WIRING DIAGRAM  620 LC4 COMPETITION  . . . . . . . . . . . . . .12-17

WIRING DIAGRAM  400 LC4  . . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM  640 LC4  . . . . . . . . . . . . . . . . . . . . . . . . .12-21

MODEL 1999
WIRING DIAGRAM  400 / 540 SXC  . . . . . . . . . . . . . . . . . . . . .12-23

WIRING DIAGRAM  400 / 540 SXC (Australia)  . . . . . . . . . . . . .12-25

WIRING DIAGRAM  400 / 620 SC   . . . . . . . . . . . . . . . . . . . . .12-27

WIRING DIAGRAM  400 / 620 SC (Australia)  . . . . . . . . . . . . . .12-29

WIRING DIAGRAM  640 ADVENTURE-R (Dell Orto)  . . . . . . . . .12-13

WIRING DIAGRAM  640 ADVENTURE-R (Mikuni) . . . . . . . . . . .12-31

WIRING DIAGRAM  640 DUKE  . . . . . . . . . . . . . . . . . . . . . . . .12-33

WIRING DIAGRAM  620 LC4 COMPETITION  . . . . . . . . . . . . . .12-17

WIRING DIAGRAM  400 LC4  . . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM  640 LC4, SUPERMOTO . . . . . . . . . . . . . . .12-21

WIRING DIAGRAM  640 LC4 (USA)  . . . . . . . . . . . . . . . . . . . . .12-11

MODEL 2000
WIRING DIAGRAM  400 / 620 SC / 620 SC SUPERMOTO . . . . .12-27

WIRING DIAGRAM  640 ADVENTURE-R   . . . . . . . . . . . . . . . . .12-31

WIRING DIAGRAM  640 DUKE  . . . . . . . . . . . . . . . . . . . . . . . .12-33

WIRING DIAGRAM  400 LC4-E  . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM  640 LC4-E, SUPERMOTO  . . . . . . . . . . . . .12-21

WIRING DIAGRAM  400 / 640 LC4-E (USA)  . . . . . . . . . . . . . . .12-35

WIRING DIAGRAMS

INDEX

12-1D

12