Adjusting Of Free Travel At The Hand Brake Lever (Lc4 Enduro); Changing The Basic Position Of The Handbrake Lever (Lc4 Supermoto); Checking Of Brake Fluid Level - Front Brake; Refilling The Front Brake Fluid Reservoir - KTM ENDURO 640 LC4 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
min. 3 mm
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Adjusting of free travel at the hand brake lever (LC4 Enduro)

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 resist-
ance you feel on the hand brake lever when the brake pads are pressed against
the brake disc) can be adjusted for any hand size. When you press the hand
brake lever forwards, you should have at least 3 mm (0.12 in) free travel. Turn
the adjusting screw [1] if necessary.
1
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 IN).
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 BRAK-
ING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.

Changing the basic position of the handbrake lever (LC4 Supermoto)

The adjusting screw [2] allows you to change the basic position of the hand-
brake lever [3].
Press the handbrake lever's outer end forward, and, at the same time, turn
the adjusting screw.
3

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 reser-
voir in a horizontal position, the brake fluid level should not go below middle
of the glass.
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.

Refilling the front brake fluid reservoir *

Loosen screws [4] and remove lid [5] and membrane [6].
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If necessary, dismount the mirror and loosen the throttle grip.
Place hand brake cylinder in a horizontal position and fill the brake fluid reser-
voir to 5 mm (0.2 in) below the rim with brake fluid DOT 5.1 (Motorex Brake
Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off spilled
or overflowing brake fluid with water.
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5 mm
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR-
PLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO
IT.
– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND
EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER
AND CONSULT A DOCTOR.
– 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.
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