User manual KTM 640 LC4 ADVENTURE-2003

[. . . ] 640 LC4 ADVENTURE BEDIENUNGSANLEITUNG OWNER'S MANUAL MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art. Nr. 3. 210. 57 9/2002 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: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! [. . . ] IF THIS FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING. Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the brake fluid level should not go below middle of the glass. WARNING 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. ENGLISH 28 3 4 2 5 mm min. 1 mm IF Refilling the front brake fluid reservoir * Loosen screws 2 and remove lid 3 and membrane 4. Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0, 2 in) below the rim with brake fluid DOT 4 (Motorex Brake Fluid DOT 4). Replace membrane and lid, tighten screws. Rinse off spilled or overflowing brake fluid with water. 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. CAUTION !­ DON'T 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. Checking the front brake pads The brake pads can be inspected from below. The linings must be at least 1 mm (0, 04 in) thick. WARNING THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON'T PUT OFF HAVING YOUR BRAKE PADS CHANGED. AT !IF CAUTION ! 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 brake pedal * 1 A The basic setting of the foot brake pedal can be changed by turning the end stop roller 1. Using the push rod 2, the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). To keep the stop roller from turning while tightening, insert a hexagon wrench in bore A. IF CAUTION ! THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND THE BRAKE PADS BEGIN TO RUB. [. . . ] Cylinder head screws Collar nuts at cylinder base Hexagon screw chain sprocket Oil drain plug Magnetic plug Plug bypass valve Hollow screws oil lines Hollow screws oil lines Jet screw clutch cover Screw plug timing-chain tensioner Counternuts valve adjusting screws Crankshaft locking bolt Spark plug Engine mounting bolt Engine mounting bolt M20x1, 5 Loctite 243 + 170 Nm M16x1, 25 left 80° C + 150 Nm M18x1, 5 Loctite 243 + 80 Nm M12x1, 5 50 Nm M6x12/M6x12, 5 Loctite 648 + 12 Nm M6 Loctite 243 + 8 Nm M10 Loctite 243 + 35 Nm M6x25/m6x35/M6x65/M6x70 (8. 8) 8 Nm M6x50/M6x55 (12. 9) 15 Nm M10 50 Nm M10 40 Nm M10 (10. 9) Loctite 243 + 60 Nm M22x1, 5 30 Nm M12x1, 5 20 Nm M12x1, 5 20 Nm M8x1 10 Nm M10x1 15 Nm M8 10 Nm M12x1, 5 20 Nm M7x0, 75 16 Nm M8 20 Nm M12x1, 25 20 Nm M8 40 Nm M10 70 Nm (125 ft. lb) (110 ft. lb) (59ft. lb) (37ft. lb) (9ft. lb) (6ft. lb) (25ft. lb) (6ft. lb) (11ft. lb) (37ft. lb) (30ft. lb) (44ft. lb) (22ft. lb) (15ft. lb) (15ft. lb) (7ft. lb) (11ft. lb) (7ft. lb) (15ft. lb) (12ft. lb) (15ft. lb) (15ft. lb) (30ft. lb) (52ft. lb) 49 ENGLISH TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2003 640 LC4 Adventure Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Tyres front Air pressure offroad Air press. road, with passenger Fuel tank capacity Final drive ratio Chain Lampenbestückung Central chrome-moly-steel frame WP USD MXMA 4860 275/300 mm (10, 5/12 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing Disc brake with carbon-steel brake disc Ø 320 mm (11, 8 in), brake caliper floated Disc brake with carbon-steel brake disc Ø 220 mm (8, 7 in), brake caliper floated 90/90-21 Enduro3 1, 8 bar (21 psi) 2, 0 bar (29 psi) 140/80-18 Enduro3 2, 0 bar (29 psi) 2, 2 bar (32 psi) 28 liter (7, 4 US gallons) of that 3, 5 liter (0, 9 US gallons) reserve 16 : 42 5/8 x 1/4 "X-Ring head light . . H1 12V 55W (Sockel P14, 5S) parking light . . 12V 2W (Sockel Ba9s) brake- rear light . [. . . ]