KTM ENDURO 640 LC4 User Manual

ENGLISH
4
INDEX »
Page
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ignition lock with 3 switch positions . . . . . . . . . . . . . .6
Multi-functional digital speedometer . . . . . . . . . . . . .7
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting options in the display . . . . . . . . . . . . . . . . . . .8
Cooling liquid temperature display . . . . . . . . . . . . . . .8
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .10
Starter tip switch, emergency OFF tip switch, light switch .10
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Compression damping of fork . . . . . . . . . . . . . . . . .12
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .12
Compression damping of shock absorber . . . . . . . . . .12
Rebound damping of shock absorber . . . . . . . . . . . . .12
Holding bars (LC4 Enduro) . . . . . . . . . . . . . . . . . . . .12
Grip (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . .12
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Instructions for initial operation . . . . . . . . . . . . . . . .13
Running in the LC4 models . . . . . . . . . . . . . . . . . . .13
Accessories and payload . . . . . . . . . . . . . . . . . . . . .13
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .14
Check the following before each start . . . . . . . . . . . .14
Starting when the engine is cold . . . . . . . . . . . . . . . .14
Starting when the engine is warm or hot . . . . . . . . . .15
What to do when the engine is „flooded” . . . . . . . . . .15
Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . .16
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .17
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .18
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .20
Tool set (LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . .20
Removing the seat (LC4 Enduro) . . . . . . . . . . . . . . . .20
Removal of seat (LC4 Supermoto) . . . . . . . . . . . . . . .21
Tool set (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . .21
Checking and adjusting steering head bearing . . . . . .21
Bleeder screws for telescopic fork . . . . . . . . . . . . . . .22
Cleaning the dust sleeves of the telescopic fork . . . . .22
Changing the spring preload of the shock absorber . . .23
Lubricating the shock absorber linkage . . . . . . . . . . .23
Checking rubber ring on the WP rear shock absorber . .23
Checking chain tension . . . . . . . . . . . . . . . . . . . . . .24
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .24
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .25
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General informations about KTM disc brakes . . . . . . .26
Page
Adjusting of free travel at the hand brake lever (LC4 Enduro) .27
Changing the basic position of the handbrake lever
(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Checking of brake fluid level - front brake . . . . . . . . .27
Refilling the front brake fluid reservoir . . . . . . . . . . .27
Checking the front brake pads (LC4 Enduro) . . . . . . .28
Checking the front brake pads (LC4 Supermoto) . . . . .28
Changing the basic position of the foot brake pedal . .28
Checking rear brake fluid level . . . . . . . . . . . . . . . . .29
Checking the rear brake pads . . . . . . . . . . . . . . . . . .29
Dismounting and mounting the front wheel (LC4 Enduro) .30
Dismounting and mounting the front wheel
(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Dismounting and mounting the rear wheel . . . . . . . . .31
Checking the shock absorption rubbers in the rear hub .31
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .32
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .32
Changing the wheel size . . . . . . . . . . . . . . . . . . . . . .32
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .33
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Exchanging the brake light and tail light bulb
(LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Exchanging the brake light and tail light bulb (LC4
Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Exchanging the headlight lamp (LC4 Enduro) . . . . . . .35
Replacing the parking-light bulb (LC4 Enduro) . . . . . .35
Exchanging the headlight lamp (LC4 Supermoto) . . . .36
Replacing the parking-light bulb (LC4 Supermoto) . . .36
Adjusting the headlight range (LC4 Supermoto) . . . . .36
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Checking the cooling liquid level . . . . . . . . . . . . . . .37
Cleaning the air filter (LC4 Enduro) . . . . . . . . . . . . . .38
Cleaning of air filter (LC4 Supermoto) . . . . . . . . . . . .38
Exhaust system (LC4 Supermoto) . . . . . . . . . . . . . . .39
Changing the original position of the clutch lever . . . .39
Checking the oil level of the hydraulic clutch . . . . . . .39
Checking and adjusting the choke cable play . . . . . . .40
Checking the adjustment of the hand decompression
cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Adjust the throttle cable . . . . . . . . . . . . . . . . . . . . .40
Activating the ignition curve for low-octane fuel . . . . .41
Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . .41
Draining the carburetor float chamber . . . . . . . . . . . .41
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Checking the engine oil level . . . . . . . . . . . . . . . . . .42
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Oil and screen filter change, bleeding of the oil system .43
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .44
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .45
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .48
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Re-initiation after time of storage . . . . . . . . . . . . . . .48
TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . .49
TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . .51
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .52
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix

KTM ENDURO 640 LC4 Specifications

General

Brand	KTM
Model	ENDURO 640 LC4
Category	Motorcycle
Language	English