User manual KTM 640 LC4

[. . . ] 640 LC4 640 LC4 SUPERMOTO BEDIENUNGSANLEITUNG OWNERS HANDBOOK MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2002 Art. Nr. 3. 210. 21 9/2001 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! [. . . ] IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC, IMPAIRING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC. Changing the basic position of the foot brake pedal* 5 4 The basic position of the foot brake pedal can be altered by turning the stop roller 4. The free play at the foot brake pedal must then be adjusted by means of the piston rod 5. Measured on the outside, the foot brake pedal must have 3-5 mm (0, 12­0, 20 in) of free play, before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). IF CAUTION ! THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE PADS. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES. 3-5mm Checking rear brake fluid level The reservoir for the rear disc brake is located on the left-hand side of the vehicle next to the carburetor carburetor connection boot. The brake fluid level may not drop below the , , MlN" marking when the vehicle is in an upright position. WARNING IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. 1 When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir. For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw 1. Then move the container outwards as indicated in the illustration. Remove plug 2 with rubber boot 3 and add brake fluid DOT 5. 1 (Shell Advance Brake DOT 5. 1) up to the , , MAX" mark. Overflown or spilled brake liquid must be rinsed off with water. Mount the screw and fix the brake fluid reservoir to the frame, always making sure to prevent kinks in the connecting hose. WARNING ­ NEVER ­ ­ ­ USE DOT5 BRAKE FLUID!IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT. STORE BRAKE FLUID OUT OF REACH OF CHILDREN. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR THE BRAKE FLUID RESERVOIRS ON THE FRONT AND REAR WHEEL BRAKES HAVE BEEN DESIGNED IN SUCH A WAY THAT EVEN IF THE BRAKE PADS ARE WORN IT IS NOT NECESSARY TO TOP UP THE BRAKE FLUID. IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. 21 !­ DON'T ­ CAUTION ! LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER. USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER. 2 3 Checking the rear brake pads min. 1 mm The brake pads can be inspected from the rear. [. . . ] permissible rear axle load 335 kg (740 lbs) Max. permissible laden weight 350 kg (773 lbs) 640 LC4 37 STANDARD ADJUSTMENT - FORK 640 LC4 WP 0518W714 20 12 4, 2 N/mm 6 mm (0, 24in) 150 mm (5, 9in) SAE 5 640 LC4 SUPERMOTO WP 0518W722 14 14 5, 0 N/mm 9 mm (0, 36in) 130 mm (5, 1in) SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 640 LC4 WP 0118W724 3 7 66 / 260 23, 5 mm(0, 94in) 640 LC4 SUPERMOTO WP 0118W721 5 7 75 / 260 15 mm(0, 6in) Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil Compression adjuster Rebound adjuster Spring Spring preload ENGLISH TIGHTENING TORQUES - CHASSIS LC4 Collar nut front axle Collar nut rear axle Shock absorber top Shock absorber bottom Collar screws brake disk front/rear Screw brake caliper front Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Ball joint for push rod Sprocket screws on nuts Collar nut swingarm bolt Clamping screws top triple clamp (USD 43) Clamping screws bottom triple clamp (USD 43) Clamping screws fork stubs Screws handlebar clamp Allan head screw handle bar support Spoke nipple Other screws on chassis M16x1, 5 M20x1, 5 M10 M10 M6 (10. 9) M8 M12 M14x1, 5 M10 M8 M8 M14x1, 5 M8 M8 M8 M8 M10 M4 M6 M8 M10 M6 M8 M10 40 Nm 80 Nm 45 Nm 45 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm 60 Nm 100 Nm 45 Nm Loctite 243 + 25 Nm Loctite 243 + 35 Nm 100 Nm 20 Nm 15 Nm 10 Nm Loctite 243 + 20 Nm Loctite 243 + 20 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm (30ft. lb) (59ft. lb) (33ft. lb) (33ft. lb) (7ft. lb) (19ft. lb) (44ft. lb) (74ft. lb) (33ft. lb) (19ft. lb) (25ft. lb) (74ft. lb) (15ft. lb) (11ft. lb) (7ft. lb) (15ft. lb) (15ft. lb) (3ft. lb) (7ft. lb) (19ft. lb) (33ft. lb) (11ft. lb) (22ft. lb) (37ft. lb) ENGLISH 38 Other collar nuts on chassis TECHNICAL DATA ­ ENGINE 640 LC4, 640 LC4 SUPERMOTO 2002 BASIC CARBURETOR SETTING 640 LC4 640 LC4 Supermoto Type Carb. -setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. screw open BST40-225 090298 142, 5 689 X-6 45 6G5 3. from top 2, 25 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 640 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 624, 6 ccm 101 / 78 mm 11 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 Intake: 36 mm Exhaust: 30 mm 0, 15 mm Exhaust: 0, 15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two Eaton-oilpumps see bellow # appr. 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