Trouble Shooting - KTM 640 LC4 Owner's Manual

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
TROUBLE
Engine doesn't crank.
The engine doesn't crank.
The neutral indicator lamp
doesn't light up.
The engine cranks only with
pulled clutch lever
Engine cranks with gear
engaged.
Engine cranks but doesn't
start.

TROUBLE SHOOTING

CAUSE
Operating errror
Discharged battery.
Defect ignition lock or emergency
OFF switch
Blown fuse safe-starting system.
Blown main fuse.
Defect safe-starting system.
Defect safe-starting system.
Operating error
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has accu-
mulated in the float chamber
Fuel supply interrupted
Flooded engine
Sooty or wet spark plug
Electrode gap too large
Spark plug connector or spark plug
faulty
The plug connection of the CDI-
unit, the pulse generator or the
ignition coil has oxydized
Water in carburetor or jets blocked
Claped out side stand
Faulty side stand switch
REMEDY
Turn on the ignition, switch the gear to neutral and switch the
emergency OFF switch on.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Check ignition lock and emergency OFF switch, contact a
KTM dealer.
Replace fuse (3).
Remove seat and replace the main fuse(1). If fuse blows again
contact a KTM dealer.
Contact a KTM dealer.
Contact a KTM dealer.
Open fuel tap, tank fuel, you did not use choke. Pay attention
to starting off information (see driving instructions).
The easily inflammable components of the new fuels evapo-
rate during longer periods of standstill.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old fuel
from the float chamber. The engine will immediately start off
when the float chamber is filled with new fuel.
Place a vessel underneath, remove the drain plug from the
carburetor and open the fuel cock,
– if fuel leaks out, the carburetor might need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Fully open the throttle when starting or exchange the spark
plug, respectively
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug elektrode gap to 0,9 mm (0.036 in)
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate starter, a strong spark
must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn't produce a spark either, dis-
connect the spark plug connector from the ignition cable,
hold it a distance of approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Remove the seat, the right side cover and the fuel tank. Clean
the plug connection and treat it with contact spray
Dismount and clean carburetor
Clap up side stand
Renew side stand switch
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