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. ! [. . . ] WARNING ­ BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0. 4 MM CONSTITUTE A SAFETY HAZARD. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON AS IT REACHES ITS WEAR LIMIT. AS A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT BY A LICENSED KTM MECHANIC. 1 ­ ENGLISH Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting screw 1. In this way, the position of the point of pressure (i. e. , the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. min. AT CAUTION ! 1 THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM. ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). 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). 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. 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. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES. 2 3-5mm 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 ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST. RE-INITIATION AFTER TIME OF STORAGE ­ ­ ­ ­ Mount the charged battery (regard polarity) and adjust the clock. Check motorcycle as before each start (see driving instructions) Take a short, careful test ride first. NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season. 47 ENGLISH TECHNICAL DATA ­ ENGINE 640 LC4 ADVENTURE 2003 Type 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 Quantity of engine oil Engine oil Primary ratio Clutch Transmission 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 625 ccm 101 / 78 mm 11, 5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 584-V03/1 Intake: 36 mm Exhaust: 30 mm Intake: 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 2 Eaton-Oilpumps see table 2. 1 liters including frame straight geared spur wheels 31 : 79 teeth multi disc clutch in oil bath, hydraulically operated 5-speed claw shifted contactless DC- CDI ignition with digital advanced system type KOKUSAN adjustment to max. 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