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KTM 640LC4 Motorcycle User Manual

1. 14 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 TOOL Sets an ee Reel 16 Removing the seat 16 Checking and adjusting steering head bearing 17 Changing the spring preload of the shock absorber 17 Lubricate shock absorber linkage 17 Checking rubber ring on the rear shock absorber 18 Checking chain 18 Correct chain tension 18 Chain maintenance eene entia 18 Chain Wear ante ea et en uera 19 General information KTM disc brakes 19 Adjisting of free travel at the hand brake lever 19 Checking of brake fluid level front 20 Refilling the front brake fluid reservoir 20 Checking the front brake 5 20 Changing the basic position of the foot brake pedal 20 Page Check the rear brake fluid level 21 Refilling the rear brake fluid reservoir 21 Checking the rear brake pads 21 Dismounting and mounting the front wheel LC4 22 Dismounting and mounting the front wheel LC4 Supermoto 22 Dismounting and mounting the rear wheel 23 Checking the shock absorbtion
2. __ 3 5 56 3NVLOO HOHV3S3U 1531 A8 Wd 0926 LY YAP 68 JO SININIHINDIH 3517 110 INIONI 3NITOSV9 NOISSIW3 3SION Vda 51330 SNOILVOI3IO3dS LNVOIUSNT 3NIDN3 SNOILVOIJIO3dS 1303 20 WW dY9 91d 4uvds 6 5 50 WA 0 JAVA NMOHS SENLOVANNVW JO ALVO SHI NO 103443 NI SIHYONVIS 3TavIsnrav NoN 3Hn1XIN 3101 A133VS HOLON 1vH3033 TIY OL SWHO ANOO FTOIH3A SIHL i aa qaas 370 2 0 dez iv Wid 80 052 44190099018 94005110018 t SAMIL 81 08 00 0 HLIM 63 052 ps9 WN SIN3Wisnrav SNOLLVOIJIOSdS dn SNNAL SNIONS Sb Isdzz Ly 2094 W3 WALSAS 10H1NOO NOISSIW3 LSNVHX3 529 1N3W3Ovdsld 579 dull Hz 06 06 62 0S Sal bee INOU4 UMVS i 54 ose 541 042 YMAD 33124138 010N18 04 60 0 VIHLSNY NSSOHDILLVW 319A9HO1O1HOdS WLY 319AOHOLON 33131340 10N180d as zooz orowaadns OVO OP9 WL HEAD WORD INDEX page Adjisting of free travel at the hand brake 19 Adjusting idling speed 28 Adjusting the choke cabl
3. 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 marking when the vehicle is in an upright position A VVARNING A 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 rear brake fluid reservoir 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 Then move the container outwards as indicated in the illustration Remove plug with rubber boot O and add brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 up to the mark Replace rubber boot and plug 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 A WARNING A 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 BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WI
4. 43 Holding bars nete 8 Ignition Jock etd eee 5 Kickstarter ee ER 7 Lubricate shock absorber linkage 17 fUSe A deo een pet e ott gre t teg 26 Maintenance work on chassis and engine 16 Oil and fine screen filter change bleeding of the oil system 31 Oilieire lt EE 31 Operation Instruments 4 Periodic Maintenance Schedule 14 Re initation after time of storage 36 Rebound damping of fork ee eee teeter tees 8 Rebound damping of shock 8 Refilling the front brake fluid reservoir 20 Refilling the rear brake fluid 21 Removing the 16 Replacing the parking light 26 Serial number locations 2 4 Shift lever cepit tte prn bens 7 Speedometer indicator lamps 5 Starter tip switch emergency OFF 6 Storage NR 36 Technical spezifications engine 38 Technical spezifications chassis 37 Tires air pressure centered 24 TOolsetz i petit tate eb ad
5. ENDURO 3 ENDURO 4 KAROO MICHELIN SIRAC T63 PIRELLI ee MT21 MT60 MT70 MT90 Tire type and size can be found in the technical specifications and in the homologation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in your country for minimum tire tread requirements We recommend replacing tires at the latest when the tread is down to 2 mm Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life of your tires A WARNING A DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES F AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become un balanced and before long other spokes will have come loose Check spoke tension especially on a new motorcyc
6. Replacing the parking light bulb Disassemble the headlight as described above and simply pull the bulb socket out of the reflector Exchanging the brake light and tail light bulb Remove the cap O on the underside of the license plate retainer Turn the lamp socket approximately 30 counterclockwise and pull it out of the tail light housing Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above Cooling system Coolant is circulated by a water pump located in the engine When the engine is cold the cooling liquid circulates only through the cylinder and the cylinder head After the engine has reached its operating temperature about 70 C 158 F the thermostat opens and the cooling liquid is also pumped through both aluminum radiators Air blowing in through the radiators cools the cooling liquid The slower the speed of the motorcycle the less the cooling liquid is cooled down Dirty radiator fins also reduce the cooling efficiency If little or no air blows through the radiators for example when riding through slow traffic or waiting at traffic lights the coolant temperature will rise If the coolant temperature rises to 85 C 185 F the fan on the left radiator will switch on This fan will provide additional air circulation through the radiator thereby preventing the cooling system from overhe
7. Driver and passenger with protective clothing and helmet Pay attention to running in instructions Running in the LC4 models Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time Therefore every engine must be run in For this reason do not demand maximum performance from the engine for the first 100 kilometers The vehicle must be run in at low changing performance level for the first 1000 KM 620 miles The engine speed of 4800 r p m must not be exceeded during the first 1000 kilometers 620 miles During this break in time you should ride your motorcycle in different conditions The following table shows you the maximum velocity values in the different gears at 4800 r p m as based on the rear wheel transmission ratio of your motorcycle Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine 640 LC4 Supermoto 16 42 t 35 22 35 Q2 50 32 50 32 70 44 70 44 90 57 90 57 100 63 100 63 km h mph NOTE DURING THE STAGE OF RUNNING THE ENGINE IN THAT IS THE FIRST 1000 KM 620 MILES THE ENGINE OIL USED SHOULD BE OF A MINERAL OIL FORMULA THIS ALSO APPLIES IF THE ENGINE HAS BEEN REPAIRED SH EPI E Starting when the engine is cold Open the fuel tap 9 Swit
8. 33 CLEANING fected RN HEREDI ep es 36 CONSERVATION FOR WINTER OPERATION 36 STORAGE dran ee HE neges 36 Re initation after time of 36 TECHNICAL SPECIFICATIONS 5515 37 TECHNICAL SPECIFICATIONS ENGINE 38 CONSUMER INFORMATION FOR USA ONLY 40 HEAD WORD INDEX sse 43 WIRING eem APPENDIX m e u ar 4 SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube Write this number into the relevant area on page 1 Engine number engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket Write this number into the relevant area on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever O is fitted on the left hand side of the handle bar When engine is cold there should allways be a play of 1 3 mm 0 04 0 1 in at this lever measured at outer edge CAUTION IF THERE IS NO PLAY ON THE CLUTCH LEVER THE CLUTCH WILL START TO SLIP THE CLUTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS Hand decompression lever The hand decompression lever is only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the
9. 10024 6 IN HY TANNVW x osna FIVANVW SYANMO 4 b IN ERI E NRI EISE E er N 53 LL J 0 Wid d5 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 A WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE Please insert the series numbers of your motorcycle in the boxes below Chassis number Engine number Stamp of dealer CONSUMER INFORMATION FOR AUSTRALIA ONLY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person KT
10. AUTHORIZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC THE BRAKE SHOE S DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN DEVIATE SIGNIFI CANTLY FROM ORIGINAL KTM BRAKE SHOES IF YOU USE DIFFERENT BRAKE SHOES THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC YOUR MOTORCYCLE WILL NOT LON GER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID BRAKE FLUID RESERVOIRS 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 wom 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 BRAKE FLUID KTM fills the brake systems with Shell Advance Brake DOT 5 1 brake fluid one of the best brake fluids that is currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible by DOT 5 1 Never use DOT 5 braking fluid It is based on silicone oil and has a purple color Gaskets and brake hoses are not compatible with it BRAKE DISCS Wear reduces the thickness of the
11. turn it back counter clockwise by as many clicks as are specified for the relevant type of fork WP 0518W714 12 Klicks 640 LC4 WP 0518W722 14 Klicks 640 LC4 Supermoto Compression damping of shock absorber With the knob the degree of damping of the compression can be adjusted to 7 positions Turn the knob counterclockwise to increase damping turn it clockwise to reduce damping during compression BASIC SETTING WP 0118W724 Position 6 640 LC4 WP 0118W721 Position 5 640 LC4 Supermoto Rebound damping of shock absorber With the setting wheel the degree of damping of the rebound can be adjusted to 11 positions Turn the knob to the left side to increase damping turn it to the right side to reduce damping during rebounding BASIC SETTING WP 0118W724 Position 7_ 640 LC4 WP 0118W721 Position 7 640 LC4 Supermoto A WARNING A NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT Holding bars The passenger can hold on to the holding bars on the rear end of the vehicle DRIVING INSTRUCTIONS Check the following before each start When you start off the motorcycle must be in a perfect tech nical condition For safety reasons you sh
12. 1500 rpm Adjusting the throttle cable When starting to turn the throttle grip you should feel an initial backlash of 3 5 mm If a correction is necessary start by removing the tank Slide back the protection cover To set the backlash loosen the counter nut and tum the adjusting screw O accordingly Then fasten the counter nut and slide the protection cover back on Make sure that the throttle grip will return to the idle position automatically once you let go of it To check the correctness of this setting start the engine turn the handlebar left and right in both cases as far as it will go This must not cause any changes in idling speed Otherwise you have to increase the backlash of the throttle cable Draining the carburetor float chamber Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the float chamber causes engine malfunction Carry out this job with the engine being cold Close the fuel tap Put one end of the hose O that leads downward behind the engine into a collecting vessel Open the drain plug turning it counterclockwise by several turns and drain the fuel from the float chamber Then retighten the drain plug and open the fuel tap A WARNING A FUEL IS HIGHLY FLAMMABLE AND TOXIC BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL NEVER PERFORM
13. AUTHORIZED KTM DEALER IMMEDIATELY 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 A AT 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 CAUTION 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 The basic position of the foot brake pedal can be altered by turning the stop roller Q The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 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 CAUTION IF 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
14. Lv YAP 68 JO SIN3W3HIQO3H SNOILv2ldIO3dS INVOIHENT 3NION3 SNOILVOIJIO3dS 13n4 NOISSIW3 ASION SLAAW SIOAQHOLOW 529078513 2002 SIHL 4 0 NW avo 9nd 4a vds 6 V38HdO MON ONA MHVAS S NOILVINHOANI NOISSINA 3SION 310A9HOLOW X3 SVO JONVEVITO 3A VA INO8V NMOHS SENLOVANNVW dO ALVO NO 103443 NI SIHVONVIS aca 1 2 AL34VS 12 HOLOW 318 21144 TIY OL SWHOJNOO 319IH3 SIHL 184 zz sdze iv Wid 11 52 nn ee 71 69 390 4109 09 HLIM 5 OSZ Sq 199 uvsu YN SIN3WIsnrav SNOILVOIJIO3dS dn 3Nnl 3NION3 oz 5482 1v 21 05 Wa INILSAS NOISSIW3 LSNVYHX3 1N3W3OY dSld 11 A8S AYIL 2402107 HLIM Dx OSL sql LEE HMVO WLYOP00IX LHE 3ALLVHOdV 3 IXULIOIXLYZ INIDNI 5 NOIL VINHOJNI TOHLNOO NOISSIW3 FTOIHaA YIHLSNY N34OHOLLLVW 319498010 A1HOdS NIX wmISnYVNISQVN 21099 VINHOSITVO NI GHVGNVLS NOISSINA OH 0 L OL SI STTOAOHOLON HWA TICON 2002 OL SNOLLYIND3H4 ANY VAI S OL SWHO4NOO 310IH3A SIHL 791099 IVNNVWN S HINMO 33 1V43Q34 AS 34V SAHVANVIS 3SION 1vH3Q34 0339X3 OL 319A9HOLOM SIHL ISNVO HOIHM NOILVOISIGOW
15. a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Exchanging the headlight lamp Remove the headlight mask Remove screws on the left and on the right side Depress the front section of the fender pull the headlight mask upwards unhook it from the lower part of the fender then swing it forwards Exchanging the headlight lamp Disconnect plug from the bulb Remove the rubber cap Unhook the retaining bracket then remove the bulb When inserting the new bulb make sure that the wider of the 3 tongues O is located in the corresponding groove in the socket CAUTION NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE HEAT WILL OTHERWISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR Hook in the retaining bracket mount the rubber cap and connect the plug to the bulb Mounting the headlight mask Appropriately position the headlight mask The headlight must be located below the cockpit Depress the front part of the fender pull the headlight mask upwards and insert the retaining pins into the corresponding bores of the fender Mount the screws
16. beginning of an on going total re engineering quality plan for a brighter tomorrow KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by SPORTMOTORCYCLE AG AUSTRIA All rights reserved Page SERIAL NUMBER LOCATIONS 4 Chassis number ine 4 Engine number engine 4 OPERATION INSTRUMENTS 00 4 Clutch leVer iir emere ht 4 Hand decompression 4 Chokelever s t tet en wee us 5 i POSUER hs 5 Speedometer indicator 5 Ignition neuen etit he eine 5 Combination switch 6 Starter tip switch emergency OFF switch 6 Filler cap c tree tee pte 6 di IE 6 Fuel esie 7 conr Be ee Han 7 Kickstarter nn Satin e a DE ER e quee 7 Foot 1 eet 7 Compression damping of fork 8 Rebound damping of fork 8 Compression damping of shock absorber 8 Rebound damping of shock absorber 8 Holding bars inst URS 8 DRIVING INSTRUCTIONS 9 PERIODIC 5
17. chain from the sprocket Carefully push the rear wheel back lift slightly and swivel to the left Carefully lift the wheel diagonally towards the rear and remove from the swing arm Do not use force to remove the rear wheel to avoid damaging the rim NOTE If the rear wheel has been dismounted you should also check the shock absorption rubber The rear wheel is remounted in reverse order Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE FOOTBRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE OTHER WISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED Checking the shock absorption rubbers in the rear hub LC4 models have a damped rear wheel hub For this purpose the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers O to the rear wheel These 6 absorption rubbers wear with increasing operation time and should be checked for wear whenever the rear wheel is dismounted For this purpose lie the rear wheel on a work bench with the rear sprocket upwards and put the wheel
18. electric starter and kickstarter Engine oil API SG SH TEMPERATUR E 10W 40 15W 40 10W 50 15W 50 Only use fully synthetic branded oils Shell Advance Ultra 4 meeting or surpassing the quality requirements of API classes SG or SH see specifica tions on the container CAUTION POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE WEAR 007 OSL 00 06 0 y LL peo y SOL peo 3481 9 WIN PPOW HdW 09 WO JDNVLSIC ONIddOLS suonipuoo 19440 Jepun 31224400 aq pue suonipuoo pue pros Jopun Aq ajqeuleyqo 5 5 JOJUI Suipeo jo suonipuoo sjoauM Adde Aayy eui Aq 10 eq UPD ey e ueuuoj1ed ayeo pul 8 siu L LNAWAAVd AJA NO JDNVLSIG ONIddOLS WNWINIW 12 seoueulpJo 220 pue a3ejs JapUN senjeued o p fqns saumo esiwau1o asn Ayuesy us s paseasoul seu esiou ji 3ueure e daJ 10 104 payday eq pjnous 3onpoud 1 N3W31VIS DNINYVM ay Aq paly aads soy uey sued uejs s ayejul 10 Jsneyxa sped apiuaA ped Sur oui Aue p eo u
19. next attempt This is due to the fact that the automatic decompressor doesn t work properly If this happens pull the manual decompression lever and start again Afterwards normal starting will be possible b When you want to push the motorcycle While pushing pull the hand decompression lever to make it easier to get the engine going CAUTION THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED SEE MAINTENANCE WORK A LACK OF PLAY IN THE HAND DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE Choke lever If the choke lever O is pulled backwards a bore will be opened in the carburetor through which the engine may draw in additional fuel This produces a rich fuel air mixture necessary for cold start If the choke lever is pushed forward up to the stop the bore will be closed again In this position the choke cable must have a play of approx 4 mm CAUTION IF THERE IS NO PLAY IN THE CHOKE CABLE THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED THIS RESULTS IN HIGH FUEL CONSUMPTION AN UNEVEN RUNNING ENGINE AND AN EXTREME WEAR OF PISTON AND CYLINDER Hand brake lever The hand brake lever is mounted on the handlebar on the right and actuates the front wheel brake A VVARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANY
20. once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation start e e e e e Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running Check brake performance Treat exposed metal components except for the braking and exhaust systems with wax based anti corrosion agents Treat ignition steering lock and light switch with contact spray Check all screws nuts and hose clamps for their tight fit MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFESSIONAL IN THE INTEREST OF YOUR OWN SAFETY HAVE THESE PROCEDURES CARRIED OUT AT A KTM SERVICE STATION AT KTM YOUR MOTORCYCLE WILL RECEIVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CON
21. pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the rear sprocket and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING UPWARDS OTHERWISE THE BRAKE DISC MAY BE DAMAGED IF THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE SHELL ADVANCE GREASE TO PREVENT THE THREAD FROM JAMMING NOTE If the rear wheel has been dismounted you should also check the shock absorption rubber The rear wheel is remounted in reverse order Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws Dismounting and mounting the rear wheel LC4 SUPERMOTO To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Remove rear screw from the chain guard To avoid damage to the rim and to fix the brake caliper stretch a rubber band or an old hose between the brake caliper and the side stand see illustration Remove collar nut remove chain tensioner hold on to the rear wheel while you pull out wheel spindle O Push the rear wheel as far forward as possible and remove the
22. screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible Remove banjo bolt and the three screws Remove oil filter cover O and oil filter Clean the filter case oil filter cover and sealing areas Make sure the oil duct in the oil filter cover is not clogged Place the new oil filter on the connection in the oil filter cover and mount together with a new seal Tighten the 3 screws in the filter cover to 5 Nm 4 ft lb Tighten the hollow screw with seals and tighten to 15 Nm 11 ft Ib Finally start the engine and check the oil system for leakage TROUBLE SHOOTING 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 CAUSE REMEDY TROUBLE Engine doesn t crank Operating errror Discharged battery Defect ignition lock or emergency OFF switch 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 The engine doesn t crank The neutral indicator lamp doesn t li
23. spindle in the hub Now hold the rear wheel firmly and try to turn the rear sprocket The rear sprocket may not turn more than maximum 5 mm 0 2 in measured on the outside If the play in the chain wheel is larger all 6 shock absorption rubbers are to be replaced Check the shock absorption rubbers for signs of damage and dirt l CAUTION IF THE SHOCK ABSORPTION RUBBERS ARE NOT REPLACED IN GOOD TIME THE REAR SPROCKET CARRIER AND THE REAR HUB WILL BE DAMAGED ALLWAYS REPLACE ALL 6 ABSORPTION RUBBERS NEVER SINGLE RUBBERS 2 J 9 2 m N TIRES AIR PRESSURE 640 LC4 front rear Road driver only 1 8 bar 26psi 2 0 bar 29psi m e E u L Road with passenger 2 0 bar 29 psi 2 2 bar 31psi 640 LC4 Supermoto front rear Road driver only 2 0 bar 29psi 2 2 bar 31psi N A Road with passenger 2 2 bar 31psi 2 4 bar 34psi Tires air pressure Tire type tire condition and how much air pressure the tires have in them affect the way your motorcycle rides and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle A WARNING A IN ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE ONLY KTM APPROVED TIRES MAY BE USED OTHER TIRES CAN HAVE A NEGATIVE EFFECT ON RIDING PERFORMANCE E G VIBRATION AT HIGHER SPEEDS Approved tires for 640 LC4 as of September 2001 METZELER
24. through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the kickstarter until you can hear the automatic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD 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 Fill up tank with fresh fuel 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 servi
25. to position 9 and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position amp and 8 Ignition lock with 3 switch positions Switch positions of ignition lock O X Ignition off light off engine can t be started O Ignition on light on engine can be started Ignition off light off handlebar blocked To switch the ignition to position amp turn the ignition key to position amp and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position X and 8 I 4 l U e 5 a HSIIDNI3 Combination switch The rocker switch LIGHTS actuates the high beam or low beam D High beam light ZD Low beam light o The indicator switch returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher bes The horn is sounded with button SO rhe light signal high beam is actuated with button O Starter tip switch emergency OFF tip switch Use the starter tip switch to operate the electric starter CAUTION MAXIMUM PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN The emergency off switch G is provided for emergency situations and should not be used to switch o
26. your seat position see maintenance work A VVARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER L 2 ml U e 7 E I 8 Compression damping of fork The compression damping is to be set at the lower end of the fork tubes It only regulates the degree of damping during compression Remove closing By using the knob O COM the degree of damping of the compression can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during compression BASIC SETTING turn rotary knob clockwise as far as it will go turn it back counter clockwise by as many clicks as are specified for the relevant type of fork WP 0518W714 20 Klicks 640 LC4 WP 0518W722 14 Klicks 640 LC4 Supermoto Rebound damping of fork The rebound damping is to be set at the upper end of the fork tubes It only regulates the degree of damping during rebounding By using the knob REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding BASIC SETTING turn rotary knob clockwise as far as it will go
27. 16 Trouble shooting sss 33 wiring diagrama us inerte tete edens Appendix 321021 KTM SPORTMOTORCYCLE AG Suspension 5230 Mattighofen WD Austria ADVANCE NE Internet www ktm at
28. ANY WORK ON THE FUEL SYSTEM NEAR OPEN FIRE OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL DOWN FIRST WIPE UP ANY SPILT FUEL IMMEDIATELY MATERIALS SATURATED WITH FUEL ARE HIGHLY FLAMMABLE AS WELL IF YOU HAVE ACCIDENTALLY SWALLOWED FUEL OR IF IT HAS GOTTEN INTO YOUR EYES GO SEE A PHYSICIAN IMMEDIATELY Adjusting the clutch cable When the engine is cold the play at the clutch lever should be 1 3 mm 0 04 0 12 in measured at the outer edge To adjust the clutch cable turn the adjusting nut accordingly J 9 2 m N Checking and adjusting the choke cable play The choke lever must always have a play of approx 4 mm 0 16 in Remove the seat and tank to adjust Push the choke lever all the way to the front and slide the protecting cap O from the adjusting part Loosen the lock nut and correct the play by turning the adjusting part Tighten lock nut and slide protecting cap back on Mount the tank and seat m e E u L w Checking the adjustment of the hand decompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kickstarter through its stroke until the clicking sound disengaging of the automatic decompression can be heard Now the decompression lever must be operated 25 mm 1 in until resistance is felt the exhaust valves begin to open To adjust move back the protective cover lo
29. D MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY DEFECT BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR e NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature O 35 C 30 95 F Do not expose to direct sun radiation Charging the battery Remove the battery and check the charging level Use a voltmeter to measure the voltage between the battery poles off load voltage off load voltage charging level charging time charging voltage Volt 26 0 8A 212 7 100 12 5 75 4h 129 50 7h 12 0 25 11h Tode 11 8 0 14h 5 CHARGING METHOD Oh or QUICK 10h Accurate results can only be obtained if the battery has neither been char ged nor discharged during a period of 30 minutes preceding the measuring If the battery is empty it can be recharged for a maximum period of 10 hours at 0 8 A and a maximum of 14 4 V CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENS
30. E OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES PLACE A CLOTH ON THE RADIATOR CAP OPEN THE CAP SLOWLY SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE CAUTION SCALDING HAZARD AND CHECK THE COOLING LIQUID LEVEL DO NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING SYSTEM HOWEVER CALL ON ONE OF KTM s DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT N THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIATELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed When driving downhill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat A WARNING A IN THE RAIN OR AFTER THE MOTORCYCLE HAS BEEN WASHED BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS FIRST THE BRAKES MUST BE BRAKED DRY SALT SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED AS WELL FIRST THE BRAKES MUST BE BRAKED CLEAN WHEN
31. ER RING IN TIME RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT Checking chain tension Support the motorcycle on the center stand or side stand respectively Switch transmission to neutral Push the chain upwards appr 30 mm 1 2 in from the end of the chain sliding component until the upper part of the chain is tensioned see illustration Now the distance between chain and swingarm should be 0 mm The upper part of the chain must be tight see illustration Correct chain tension if necessary A WARNING A IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY POWER TRANS MISSION CHAIN CHAIN SPROCKETS TRANSMISSION AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNECESSARY STRESS RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE EITHER CASE THE OPERATOR IS LIKELY LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut O loosen counter nuts and turn right and left adjusting screws O equally far Tighten counter nuts Before tightening the wheel spindle verify that the chain adj
32. IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE A mixture of 40 antifreezer and 60 water is used as cooling liquid How ever the anti freeze protection must be at least 25 C 13 F Aside from antifreezing protection this mixture also provides great corrosion protection which is why it must not be replaced by pure water CAUTION l FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZER SHELL ADVANCE COOLANT USING LOWERGRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap a water temperature rising up to 120 C 248 F is admissible without fear of problems J 9 2 m N 10 mm when engine is cold HSII1DN3 N Checking the cooling liquid level The cooling liquid should be 10 mm 0 4 in above the cooling elements when the engine is cold cf diagram In the event of the cooling liquid being drained always fill the system before hand then top off while the engine is running A VVARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Cleaning the air filter It is very important for the engine s life expectancy to clean the air filter regular
33. M SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI TUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL DEALER FOR INFORMATION WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS 2 E u I 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled ou
34. MORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Speedometer indicator lamps The mileage indicator in the speedometer indicates overall mileage The day mileage indicator can be set to O by means of the setting wheel Turn the setting wheel forward until only zeros can be seen in the display The green indicator lamp flashes when the flasher light is working in the same rhythm as the flasher light N The green indicator lamp lights up when the gear is switched to idle D The blue indicator lamp lights up when the high beam is on E The red cooling liquid temperature warning lamp lights up at a cooling liquid temperature of 105 C 223 F CAUTION POSSIBLE CAUSES FOR THE RISE IN TEMPERATURE AND THE LIGHTING OF THE RED COOLING LIQUID TEMPEREATURE WARNING LIGHT SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE TOO LITTLE COOLING LIQUID IN THE SYSTEM THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING EXCESSIVE USE OF THE CLUTCH AT SLOW SPEED SEE PAGE 27 Ignition lock with 4 switch positions Switch positions of ignition lock O X Ignition off light off engine can t be started O Ignition on light off engine can be started O Ignition on light on engine can be started Riding just with lights Ignition off light off handlebar blocked To switch the ignition to position amp turn the ignition key
35. N OUII OH BY 5 3noqe uomneuuojul 19440 urejqo osje ue 706600 DA uojSutuseAA uoneuodsuej jo juaumredeq SN VSIHN 0 m JO q uojguysem ul ECLO 99 10 E6E6 777 008 1 19 994 0 419195 ojny 62 y no YSIHN Pejuoo OL YSN 9pKo1030un40dS WLX 40 NOK ur jouue YSLHN JaAamoH uSredureo pue 2 Jopio sap yaa 8 e ui 5351 pajap 3 yey spuy 31 pue 8 ue Uado y sjurejduioo Jejus WSLHN OUI WSN e o1030un40dS WL 0 uonipe VSLHN Aj9jes 8 euoneN eui wozu pjnous yyeap Jo esne p noo use gt sey yey ans laq 4 12333G A133VS ONILHOdII AINO WSN NOILVWIOINI JIWNSNOD 7 09 F OS N NAT 1v93q34 ALVIOIA AVW PE pm E N TVONVW SY3NMO JHL OL 93334 431512345 LON SATDADYOLOW NO WALSAS 4 AvW 2OHS JHL ISNvHXI SIHL dO NOILVTIVISNI Sc90v8S N JONIS IDOHS ONIGTINGIY YO WL 21412445 TIAOW V8P 08 JO 2 DONITIIJ3H LdWILLV LON OG 3WfnS SLNIWIAINDIY
36. NECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES IF THE MOTORCYCLE SHOULD FALL OVER FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK Do NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OIL GREASE FILTERS FUELS CLEANING AGENTS ETC ACCORDING TO YOUR LOCAL REGULATIONS UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER USED OIL CONTAMINATES 1 000 000 LITERS WATER IF YOU UNFASTEN SELF LOCKING NUTS YOU HAVE TO REPLACE THEM BY NEW ONES IF YOU UNFASTEN SCREWS AND NUTS SECURED BY LOCTITE YOU HAVE TO REATTACH AND SECURE THEM IN THE SAME WAY SEE TECHNICAL SPECIFI CATIONS FASTENING TORQUES ON PAGE 39 m e x u Tool set The tool set is located in the tool box under the right side cover Removing the seat Remove the collar screws from the underside of the fender Lift the rear of the seat pull backwards and unhook it from the oval head screw To mount the seat hook it into the oval head screw lower the rear part of d the seat and push the whole seat forwards If necessary push the middle of the se
37. NOISSIW3 3SION S133W e gt S3Hd HOIH SVD NIDONLIN 00T 80 80 88 WILSAS ISNVHXI WIN SIHL 5 2 a SNIVLNOD 3g4OSg8V MDOHS SIHL Xe DNIN3VM 3 v210t9 00t ATINJ3UVI S H3NMO 1 OVS 1 30122 NI 170538 AVN SNOILINULSNI ONILVHIdO ONILHVIS MOT104 01 IHNTIVAI E 3H1 1081 059 01 HOLVHIdO 30 ALINIAY FHL 19343V A13S83AQV VIM H39N3SSVd V 30 NOILIQQV 3HL SU39N3SSVd ON ATNO HO1V 8340 E ANNO JSN QVOU 330 E 13W13H VIM SAVMIV E SNINHVM Y 3191H3 VINSO3I TV WLYOPOOIXLYX 1 80 2 419 OIXLYX ATAY3 SNIONA 10 INILNOS 3508 WANIYA 2007 orowaadns OVO 1 079 WL VISLSNV NI 991099 NI GHVONVLS NOISSINI OH 0 1 OL 431511930 SI SATOAOHOLOW TAGOW 2002 OL 318v9llddv SNOLLV Tn 93H ANY Vd3 S N OL SNHOJNOO 310IH3A SIHL VISLSNV NI 3QVNW 791099 WANVW S H3NMO 33S 1v43Q034 38V SAUVANVLS 3SION 1 Q330X3 OL 319A9HOLOM SIH L ISNVO HOIHM NOILVOISIGOW Ov MSL AVS 3dAL 56 HOHV3S3H 3Wv31319NI S3H1I1 L Z TIO 3NION3 a3aava nn 3QvH9 105 9 1931 1Y43034 Ad 0926
38. RFILL THE ENGINE CASE DO NOT UNDERFILL THE ENGINE CASE Finally check oil system and engine for leaks CLERI Oil circuit The oil pump O pumps the motor oil past the bypass valve O and through the oil filter O Beyond the oil filter one of the oil lines forks off to a jet that injects motor oil to the piston pin bearing and the piston head The second oil line leads the main oil flow to the frame breast pipe where the motor oil is cooled off Then the motor oil flows through the fine screen filter O that removes even the finest of contaminants from the motor oil The cleansed motor oil is pumped via an oil line and the clutch cover into the crankshaft to the conrod bearing and drains from there into the crank case A additional oil pump O suctions the motor oil out of the crank case and pumps it through the oil canal O to the gear wheels of the 4th and 5th gears The motor oil reaches the oil sump via the gear wheels The timing chain also dips into the oil sump and propels motor oil upwards to the cylinder head The motor oil reaches the carnshaft and the valves through the bore Oil and screen filter c
39. Recharge the battery according to the relevant instructions Remove seat and check voltage regulator connections voltage regulator and generator should be checked by a KTM dealer CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge The hard dirt can be removed before with the help of a soft water jet CAUTION l NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBINGS OR LEAD TO A PREMATURE DESTRUC TION OF THESE PARTS You should use normal trade mark detergents to clean the engine Strongly dirted parts should be cleaned additionally with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes Due to the heat the water also evaporates at the unapproachable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all s
40. TH 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 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 rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in A WARNING A AT 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 CAUTION 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 IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC J 9 2 m N imb 2 N Dismounting and mounting the front wheel LC4 To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen both clamp screws on the left fork leg Then loosen t
41. TY OF TIME WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A DEFORMED HANDLEBAR MUST ALWAYS BE REPLACED UNDER NO CIRCUMSTANCES SHOULD YOU STRAIGHTEN THE HANDLEBAR WHICH WOULD CONSEQUENTLY LOSE ITS STABILITY CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVERSPEED DAMAGING THE VALVES IN ADDITION THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO ENGINE DAMAGE NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT TEMPERATURE HAS REACHED 105 c POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR TEMPERATURES LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT FAN AT LEFT RADIATOR IS NOT RUNNING IMPROPER US
42. This is easily done NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring changes the spring preload by approximately 1 75 mm 0 07 in Loosen the locking ring O with the hook wrench from the tool set Change the spring preload with the adjusting ring and retighten the locking ring BASIC SETTING SPRING PRELOAD WP 0118W724 A 23 5mm 640 LC4 WP 0118W721 A 15mm 640 LC4 Supermoto Lubricating the shock absorber linkage The bearings in the rocker arm must be greased Shell Advance Grease in regular intervals For this purpose a grease nipple is mounted on the rocker arm CAUTION AFTER EACH TIME THE MOTORCYCLE IS WASHED IT IS ESPECIALLY IMPORTANT TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS gt 0 Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibration damper This ring gets pressed together with time and loses its shock absorbing quality Measure the distance between the two discs at various points around their circumferences The space should be at least 2 5 mm 0 1 in wide Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit CAUTION NOT REPLACING THE RUBB
43. URE SUFFICIENT VENTI LATION EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES AVOID QUICK CHARGING IF POSSIBLE J e m N u Main fuse Located near the battery under the seat the main fuse O protects all power consumers Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 20 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Fuses for individual power consuming units Additional fuses separately protecting different power consuming units are mounted under the headlight mask For instructions to remove and mount the headlight mask please refer to Exchanging the headlight lamp Fuse 10 Ampere protects the following power consuming units headlight parking light Fuse O 10 Ampere protects the following power consuming units flasher lights brake light horn radiator fan motor Fuse O 10 Ampere protects the following power consuming units ignition starter system Replace
44. YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BRAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL Stopping and parking Apply the brakes fully and put the engine into neutral To stop the engine switch off the ignition Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle A WARNING A ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE ENGINE RADIATORS EXHAUST EXHAUST SYSTEM BRAKE DISCS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS CAUTION CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS aigu 12 NOTE REGARDING THE CENTER STAND We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible a press main stand t
45. ar nut rear axle M20x1 5 80 Nm 59ft Ib Shock absorber top M10 45 Nm 33ft Ib Shock absorber bottom M10 45 Nm 33ft lb Collar screws brake disk front rear M6 10 9 Loctite 243 10 Nm 7ft Ib Screw brake caliper front M8 Loctite 243 25 Nm 19ft Ib Bearing bolt linkage arm frame M12 60 Nm 446 16 Collar nuts rocker arm bolts M14x1 5 100 Nm 746 16 Engine mounting screw M10 45 Nm 33ft lb Ball joint for push rod M8 Loctite 243 25 Nm 19ft Ib Sprocket screws on nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swingarm bolt M14x1 5 100 Nm 74ft lb Clamping screws top triple clamp USD 43 M8 20 Nm 15ft Ib Clamping screws bottom triple clamp USD 43 M8 15 Nm 11ft Ib Clamping screws fork stubs M8 10 Nm 716 Screws handlebar clamp M8 Loctite 243 20 Nm 15ft Ib Allan head screw handle bar support M10 Loctite 243 20 Nm 15ft Ib Spoke nipple 4 3ft Ib Other screws on chassis M6 10 Nm 7ft Ib M8 25 Nm 19ft Ib M10 45 Nm 33ft Ib Other collar nuts on chassis M6 15 Nm 11ft Ib M8 30 Nm Q2ft Ib M10 50 Nm 37ft Ib TECHNICAL DATA ENGINE 640 LC4 640 LC4 SUPERMOTO 2002 BASIC CARBURETOR SETTING 640 LC4 640 LC4 Supermoto Type BST40 225 Carb setting number 090298 Main jet 142 5 Needle jet 689 X 6 Idling jet 45 Jet needle 605 Needle clip pos f top 3 from top Mixt adj screw open 2 25 Engine 640 LC4 Design Liquid cooled s
46. at slightly down to let the retaining bracket engage with the seat Finally fasten the seat with the corresponding screw Checking and adjusting steering head bearing Check steering head bearing for play periodicaly To check this put motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust loosen the five clamp screws O of the top triple clamp and turn steering stem bolt clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to avoid tension Re tighten the five clamp screws with 15 Nm 11 116 A VVARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTOR CYCLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED At least once a year the steering head bearings should be greased 2 J 9 2 m ES m Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only weighing approximately 75 kg 165 Ib If you want to take a passenger with you of if you weigh considerably more or less than 75 kg 165 Ib you should change the spring preload accordingly
47. ating CAUTION THE RED COOLING LIQUID TEMPERATURE WARNING LIGHT WILL BEGIN TO LIGHT UP IF THE COOLING LIQUID TEMPERATURE REACHES APPROX 105 C 223 F AND HENCEFORTH HAS EXCEEDED ITS NORMAL OPERATING TEMPERATURE POSSIBLE CAUSES SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE IF POSSIBLE INCREASE YOUR RUNNING SPEED SO THAT MORE AIR CAN BLOW THROUGH THE RADIATORS SHOULD THE WARNING LIGHT STILL BE ON OFF AFTER 300 METERS STOP IMMEDIATELY SWITCH OFF THE ENGINE AND LOOK FOR OTHER POSSIBLE CAUSES TOO LITTLE COOLING LIQUID IN THE SYSTEM LET THE ENGINE COOL DOWN AND CHECK THE SYSTEM FOR LEAKAGE S ALSO EXAMINE THE COOLING LIQUID LEVEL CAUTION SCALDING HAZARD Do NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM GO TO YOUR NEAREST KTM GARAGE AND GET IT SEEN TO IF YOU DRIVE WITH THE COOLING LIQUID TEMPERATURE WARNING LIGHT ON YOU WILL CAUSE EVEN MORE DAMAGES TO THE ENGINE THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING THE COOLING FAN MUST BE RUNNING WHEN THE COOLING LIQUID TEMPERATURE IS 105 C 223 F AND THE IGNITION IS ON IF THE FAN IS NOT WORKING AND THERE APPEARS TO BE SUFFICIENT COOLING LIQUID THE ONLY THING YOU CAN DO IS TO DRIVE ON TO YOUR NEAREST KTM GARAGE AT THE LEAST POSSIBLE ENGINE LOAD EXCESSIVE USE OF THE CLUTCH AT SLOW SPEED A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE
48. brake disc in the area of contact O with the brake pads At its thinnest spot the brake disc must not be more than 0 4mm thinner than its nominal dimension The nominal dimension can be gaged in a location beyond the area of contact with the brake pads Check wear in several spots A VVARNING A 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 S A MATTER OF PRINCIPLE HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT BY A LICENSED KTM MECHANIC Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting screw 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 CAUTION AT 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 lF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING imb N 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 wit
49. bricate reversing lever Check all chassis screws for tight fit fork plates fork leg axle nuts screws swinging fork pivot reversing lever suspension strut Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear force fit and tension Check screws on pinion and chain sprocket for locking devices and a tight fit WHEELS Lubricate chain Check wheel bearings and jerk damper for play IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least every 2 years once ayear or 20000 km Perform complete fork maintenance e Perform complete suspension strut maintenance e Perform complete reversing lever maintenance e Clean and lubricate steering head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5OO KM MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every cleaning for cross country use
50. ce 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 TECHNICAL SPECIFICATIONS CHASSIS 640 LC4 640 LC4 SUPERMOTO 2002 640 LC4 640 LC4 Supermoto Central chrome moly steel frame White Power Up Side Down 4357 MXMA 270 300 mm 10 6 11 8 in Central shock absorber WP BAVP3612 with PRO LEVER linkage to rear swing arm with needle bearing Disc brake with carbon steel brake disc brake caliper floated 300 mm 11 8 in 320 mm 12 6 in Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated 90 90 21 120 70 17 Frame Fork Wheel travel front rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press road driver only Air press road with passenger 1 8 bar 26 psi 2 0 bar 29 psi 2 0 bar 29 psi 2 2 bar 31 psi Tyres rear Air press road driver only Air press road with passenger 140 80 18 2 0 bar 29 psi 2 2 bar 31 psi 160 60 17 2 2 bar 31 psi 2 4 bar 34 psi Fuel tank capacity 11 or 18 liter 2 9 or 4 8 US gallons 2 5 liter 0 6 US gallons reserve 4 J U e m Final drive ratio 16 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43
51. ch on ignition turn ignition key into position Switch on emergency OFF switch 0 Switch transmission to idle green indicator lamp N lights up Operate cold starting device choke Do not accelerate operate starter button If the engine starts push the choke lever back a little bit as soon as the engine runs unevenly Take the motorcycle off of the main stand or side stand A WARNING A TO AVOID INJURIES IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING cauUTION I 9 MAXIMUM PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on ignition lock in position If this is not the case the battery is discharged If the lights ar
52. e 30 Adjusting the clutch cable 29 Adjusting the throttle cable 29 Battery a ee 25 Chain maintenance en 18 Chain Weal cni eei t ip Es 19 Changing oil filter ws cn tte ette tes 32 Changing the basic position of the foot brake pedal 20 Changing the fine screen filter 31 Changing the spring preload of the shock absorber 17 Charging the battery 25 Chassis 4 Check the rear brake fluid 21 Checking and adjusting steering head bearing 17 Checking chain tension 18 Checking of brake fluid level front brake 20 Checking rubber ring on the rear shock absorber 18 Checking spoke tension 24 Checking the adjustment of the hand decompression cable 30 Checking the cooling liquid 28 Checking the engine oil level 30 Checking the front brake pads 20 Checking the rear brake 21 Checking the shock absorbtion
53. e on proceed as described in the Trouble shooting section or contact a KTM dealer IF THE ENGINE CRANKS BUT DOES NOT START WHEN YOU ACTUATE THE STARTER TIP SWITCH Check if the fuel tap is open Check if the choke lever has been operated Check if sufficient fuel is in the tank f this is not the case refill the tank if sufficient fuel is in the tank proceed as described in the Trouble shooting section or contact a KTM dealer NOTE LC4 This motorcycle is equipped with a safety starter system The engine can only be started when the transmission is switched to idle or the clutch lever is pulled respectively NOTE LC4 SUPERMOTO This motorcycle is equipped with a safety starter system The engine can only be started when the transmission is switched to idle or the clutch lever is pulled respectively Motorcycles with side stands are also equipped with a safety starting system If you put in a gear with the side stand in its swung out position and if you let go of the clutch lever the engine will stop Starting when the engine is warm or hot Open the fuel tap 9 Switch on ignition turn ignition key into position O Switch on emergency OFF switch Switch transmission to idle green indicator lamp N lights up Do not accelerate operate starter button Take the motorcycle off of the main stand or side stand NORWN gt What to do when the engine is flooded The throttle must be ful
54. el of cooling liquid when the engine is cold ELECTRICAL SYSTEM Check headlight parking light tail light brake light flashers indicator lamps and horn for faultless operation LUGGAGE If you are taking luggage with you check that this is securely fastened A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE YOUR PASSENGER OF COURSE WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM FOR EXAMPLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE S DRIVING PROPERTIES THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service Manual Read the entire manual carefully before your first drive Familiarize yourself with the operating elements Adjust the hand brake lever and the foot brake pedal to t
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56. ff the engine The engine is ready for operation in position O ignition circuit and starter circuit are switched on The engine cannot be started in position X ignition circuit and starter circuit are interrupted Filler cap The filler cap amp can be locked and is provided with a fuel evaporation control system To open the cap insert the ignition key turn it 90 counterclockwise then lift off the filler cap To close the tank insert the filler cap turn the ignition key 90 clockwise and take out the key Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE A WARNING A GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON When using the motorcycle the twis
57. g the throttle grip all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Never open the throttle wider than the engine can handle Excessive turning of the throttle grip will increase full consumption By shifting down use the brakes if necessary and close throttle at the same time Pull clutch lever and shift down to the next gear Let clutch lever go slowely and open throttle or shift down again If the engine is killed f ex at a crossing simply pull the clutch lever and start It is not necessary to switch the gear to NEUTRAL A WARNING A OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND OTHERWISE YOU MIGHT EASILY LOSE CONTROL OVER YOUR MOTORCYCLE WHILE RIDING YOUR MOTORCYCLE NEVER SWITCH THE IGNITION LOCK TO POSITIONS X AND RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLEN
58. ght up Blown fuse safe starting system Blown main fuse Replace fuse below the headlight mask Remove seat and replace the main fuse If fuse blows again contact a KTM dealer The engine cranks only with pulled clutch lever Defect safe starting system Contact a KTM dealer Engine cranks engaged with gear Defect safe starting system Contact a KTM dealer Engine cranks but doesn t start 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 Open fuel tap tank fuel you did not use choke i e the warm start device 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
59. h an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass A WARNING A 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 and remove lid O and membrane 6 If necessary dismount the mirror and loosen the throttle grip 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 5 1 Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A 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 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 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
60. hange bleeding of the oil system Note The frame breast pipe is integrated into the oil circuit for the sake of more effectively cooling the motor oil It is thus important when changing the oil to also remove the fine screen filter to drain the motor oil from the breast pipe and to de aerate the oil system If the oil system is not bled at all or bled insufficiently the bearings of the engine will not get enough lubrication which in turn may result in engine failure Therefore we recommend that you have the engine oil changed by your authorized KTM mechanic During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried out when the engine is still warm A VVARNING A AN ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT IS VERY HOT DO NOT BURN YOURSELF Place the motorcycle on a horizontal surface Remove the two plugs and and drain oil into a container CAUTION PLUG MUST NOT BE REMOVED THIS IS PART OF THE BY PASS VALVE Remove the screws and the cover Loosen the fine screen filter with an oil filter wrench and then screw it off by hand The screw must be removed to allow the motor oil to flow out of the frame breast pipe Clean the plugs thoroughly with petroleum and compressed air in order to remove any metal filings After the oil has drained completely clean the sealing areas and remoun
61. he most comfortable positions for you Get used to handling the motorcycle on an empty car park before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your ability and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake pedal when you are not braking If the foot brake pedal is not released the brake pads rub continuously and the braking system is overheated You may only be accompanied by a passenger if your motorcycle is fitted and registered for such purposes The passenger must hold tight to the brackets or hold on to the driver during the drive with his feet on the passenger foot rests Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage
62. he collar nuts O before loosening the clamp screws on the right fork leg Hold the front wheel and withdraw the wheel spindle Note The wheel spindle can be withdrawn more easily by turning it mode rately with a 6 mm ALLAN IMBUS key while pulling Remove front wheel carefully from the fork and take the speedometer drive off the hub CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING UPWARDS OTHERWISE THE BRAKE DISC MAY BE DAMAGED Prior to mounting the front wheel clean and grease sealing ring O and running surface at the speedometer drive To mount the front wheel lift it into the fork Insert speedometer drive into the hub Make sure that the driving tabs engage with the slots of the drive Position front wheel and speedometer drive and mount wheel spindle The speedometer shaft must be placed as running along the outsideof the fork guard and pass the triple clamp in front between fender and fork leg Screw on the collar nuts O without tightening them Make sure that the speedometer drive runs upwards and parallel to the fork leg see below Tighten the clamp screws on the right fork leg so as to prevent the wheel spindle from twisting and then tighten the collar nuts with 40 Nm Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down o
63. ingle cylinder 4 stroke engine with balancer shaft and electric starter Displacement 624 6 ccm Bore Stroke 101 78 mm Ratio 11 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Camshaft 249 1 Valve diameter Intake 36 mm Exhaust 30 mm Valve clearence cold 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston forged cast aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication two Eaton oilpumps Engine oil see bellow Engine oil quantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max 38 BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DPR8 EA9 Spark plug gap 0 9 mm Cooling system liquid cooled permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter 40 antifreeze 60 water atleast 25 13 F Starting equipment
64. is perma nently activated due to a lack of play in the choke cable Defective membrane of slide Carburetor leaking Loose carburettor jets Electronic ignition timing faulty Dismount carburetor and check if worn out Replace float needle Replace float Adjust choke cable Replace membrane Check vacuum hose and venting hose of carburetor for correct position no kinks Tighten jets Have ignition system checked Engine will not reach full power Fuel supply partically interrupted or carburetor dirty Float leaks Defective membrane of slide Carburetor leaking Air filter very dirty Valve clearance to small Loss of compression because hand decompressor has no play Electronic ignition timing faulty Clean and check fuel system as well as carburetor Replace the float Replace membrane Check vacuum hose and venting hose of carburetor for correct position no kinks Clean or replace air filter contact a KTM dealer Have valve clearance adjusted Check setting of the hand decompression cable Have ignition system checked Engine overheats Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Bent radiator hose Thermostat defective Blown fan fuse Defect thermoswitch Fan defective Refill cooling liquid see maintenace work check cooling system for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Shor
65. just valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting CARBURETOR Check bleeder hoses for damage and kink free arrangement Check cooling system for leaks antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension e Check actuating cables for damage smooth operation and kink less arrangement adjust and lubricate them e Clean air filter and air filter box Check cables for damage and kink less arrangement Check headlamp adjustment ADD ON PARTS Check electrical system for function low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws and nuts are tight Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks BRAKES Check adjust smooth operation free travel of handbrake footbrake levers Check screws of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging fork pivot CHASSIS eoe Check adjust steering head bearing Lu
66. le in regular intervals For checking tap on each spoke with the blade of a screw driver see illustration A clear tone must be the result Dull tones indicate loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPOKES MUST BE TENSIONED TO 4 NM Battery The battery is mounted under the seat remove the seat see page 16 The battery has a closed system and therefore requires no maintenance It is not necessary to check the electrolyte level or to refill water Simply keep the battery poles clean and slightly grease them with an acid free grease if necessary Removing the battery First disconnect the negative and then the positive pole of the battery Remove screws and swing retaining bracket and voltage regulator out of the way Remove battery When replacing connect first the positive and then the negative pole A WARNING A IF ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER IN THE CASE OF CONTACT WITH THE EYES THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES IMMEDIATELY CONSULT A DOCTOR THE BATTERY IS A CLOSE
67. liding and pivot points Treat the chain with a chain spray too To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch light switch and the socket connectors with contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt clean motorcycle thoroughly and let it dry treat engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corrosion agent A WARNING A KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER l CAUTION I AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE Should you desire to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil oil filter and fine screen filter old engine oil contains aggressive contaminations Check antifreezer and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder
68. ly To clean the air filter remove screws O and the filter box cover Detach retaining clip O and remove the air filter O including the filter holder O from the filter box Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid Products required for a professional maintenance of the air filter are available from TWIN AIR Press out the water from the air filter but do not wring and allow the filter to dry Lubricate the dry air filter thoroughly with high grade filter oil rubbing to coat the entire filter surface Clean the filter box and cover and check the carburetor connection boot for damage Mount the air filter on the filter holder position in the filter box make sure to center and fix with the retaining clip Check whether the air filter is positioned correctly and mount the filter box cover CAUTION DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS NOT MOUNTED CORRECTLY Adjust idling speed Use the adjusting screw to adjust the basic position of the throttle valve and thus the idle speed Turning in clockwise direction will increase the idling speed turning in counterclockwise direction will reduce the idling speed Normal idling speed 1400
69. ly opened when starting If necessary change spark plug Kickstart instructions Start as described above then push the kickstarter hard ALL THE WAY A WARNING A WHEN STARTING THE ENGINE MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY YOU MIGHT SLIDE OFF THE KICKSTARTER OR THE ENGINE MAY CAUSE THE KICKSTARTER TO RECOIL THEREBY CAUSING INJURIES TO FOOT AND LEG ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND WHILE DOING SO NEVER OPEN THE THROTTLE KICKSTARTING WITH INSUFFICIENT MOMENTUM AND AN OPENED THROTTLE LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open throttle at the same time A WARNING A BEFORE YOU START OFF CHECK THAT THE MAIN STAND HAS BEEN SWUNG UP FULLY IF THE STAND DRAGS ON THE GROUND THE MOTORCYCLE CAN GO OUT OF CONTROL ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the conditions traffic road gradient etc you can shift to a higher gear Close throttle at the same time pull clutch lever and shift to the next higher gear Let clutch lever go again and open throttle If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through turnin
70. n the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 10 Nm 7 ft Ibs A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED Dismounting and mounting the front wheel LC4 Supermoto The front wheel of the Supermoto is essentially removed in the same manner as the front wheel of the LC4 E However the brake caliper has first to be removed To remove the front brake caliper remove both screws O and pull the caliper backwards from the brake disc After mounting the front wheel slide the brake caliper to the brake disc Remove the grease from the threads of both screws O and apply Loctite 243 Tighten the screws with 25 Nm 19 ft Ibs A WARNING A THE SCREWS O MUST BE SECURED WITH LOCTITE 243 Dismounting and mounting the rear wheel LC4 Park the motorcycle on the center stand The rear wheel must not touch the ground Loosen the collar nut remove chain tensioner hold the rear wheel and
71. o ground using foot b swing out kickstarter and pull motorcycle backwards at an angle as illustrated see illustration Make sure that the ground is solid and that your motorcycle is standing securely CAUTION THE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY Bv SITTING ON THE MOTORCYCLE YOU WILL PUT ADDITIONAL WEIGHT ON THE CENTER STAND POSSIBLY CAUSING THE CENTER STAND OR FRAME TO BE DAMAGED OR THE MOTORCYCLE TO FALL DOWN INFORMATION ABOUT THE SIDE STAND Use your foot to push the side stand forward as far as possible and lean your motorcycle to the side Make sure that your motorcycle is standing safely on solid ground Just in case you can also put in a gear CAUTION THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE STAND YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME AND YOUR MOTORBIKE MAY FALL OVER HSITDONGA 640 LC4 PERIODIC MAINTENANCE SCHEDULE a 1 Service 2 Service after after 5000 km then 1000 km every 5000 km or once a year A washed motorcycle can be checked more quickly which saves money Change engine oil oil filter and fine filter e Clean oil screens and magnet of drain plug e Check oil lines for damage and kink less arrangement e Check and adjust spark plug replace it every 10 000 km ENGINE Check and ad
72. osen the counter nut and correct the adjusting screw accordingly Tighten counter nut and push back protective cover CAUTION IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made to the automatic decompressor Engine oil Only use fully synthetic branded oils Shell Advance Ultra 4 meeting or sur API SG SH passing the quality requirements of API classes SG or SH see specifications on the container TEMPERATUR CAUTION H 0 C INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE 32 F 10W 40 15W 40 10W 50 45W 50 Checking engine oil level Allow the engine to run at idle speed for about 4 minutes Turn off the engine and place the motorcycle on a flat level surface center stand Wait 5 minutes unscrew and remove the oil dipstick and wipe it clean with a cloth SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN The oil level should be between the two marks on the dipstick however it must never rise above the MAX mark Otherwise engine oil would get into the air filter box by way of the engine venting system Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL Do NOT OVE
73. ould make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OlL LEVEL Insufficient oil results in premature wear and consequently to engine damage FUEL Check that there is sufficient fuel in the tank when closing the filler cap CHAIN A loose chain can fall off an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and rear sprockets TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure reduce the driving performance BRAKES Check the brakes for proper functioning as well as the brake fluid level in the tanks The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a specialist garage as complete failure of the braking system can be expected Also check the state of the brake hoses and the thickness of the brake linings Check free travel at hand brake lever and foot brake pedal CABLES Check correct setting and easy running of all control cables COOLING LIQUID Check the lev
74. rubbers in the rear hub 23 Choke inicie i 5 Cleaning ee t ce d ame ien eaten 36 Cleaning the air filter 28 Clutch lever er meme 4 Combination 2 6 Compression damping of 8 Compression damping of shock 8 Conservation for Winter 36 Consumer Information for USA only 40 Cooling systemens sorin Ee Ee 27 Gortect ch in tension tan ann 18 Dismounting and mounting the front wheel 22 Dismounting and mounting the rear wheel 23 Draining the carburetor float chamber 29 Driving Instructions sssssssse ee 9 page Engine number engine 4 ret bem E Det 30 Exchanging the brake light and tail light bulb 27 Exchanging the headlight lamp eee 26 teat uto 6 Foot brake ur detecte eterne 7 F lle c m tat 6 tue idan 7 Fuses for individual power consuming units 26 General information on KTM disc brakes 19 Hand brake lever st e eee 5 Hand decompression lever 4 Head word
75. rubbers in the rear hub 23 Tires alr pressute irte hores 24 Checking spoke 24 Battery ipte eme 25 Charging the battery 25 enter 26 Fuses for individual power consuming units 26 Exchanging the headlight lamp 26 Replacing the parking light bulb 26 Exchanging the brake light and tail light bulb 27 Cooling 27 Checking the cooling liquid level 28 Cleaning the air filter 28 Adjusting idling speed 28 Adjusting the throttle cable 29 Draining the carburetor float 29 Adjusting the clutch 29 Checking and adjusting the chocke cable play 30 Checking the adjustment of the hand decompression cable 30 Engine Oll alter tide te et e es 30 Checking the engine oil 30 Oil Circuit tea et 31 Oil and fine screen filter change bleeding of the oil system 31 Changing oil filter oo sss 32 TROUBLE 5
76. s Shift the gear into idling and pull the upper chain strand with approx 10 15 kilogramm 33 Ib upwards see figure Now can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets General informations about KTM disc brakes BRAKE CALIPERS The brake calipers of this series float This means that the brake calipers are not solidly attached to the caliper support Thus the brake pads are always in optimum contact with the brake disc Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm 19 ft Ib BRAKE PADS The motorcycles are delivered with organic brake pads and have also been type coded with these pads Said pads are suitable for almost the entire range of application of these motorcycles It is only for competitive racing in extremely dirty conditions e g water in combination with sand and mud that we recommend brake pads that have sintered linings However take notice of the fact that brake pads with sintered linings have not been type coded Besides they may cause greater wear on the brake discs WARNING BRAKE SHOES AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN
77. t however that there may exist minor discrepancies resulting from further design upgrades of these motorcycles This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked described in the chapter entitled Maintenance Work on Chassis and Engine of this manual For your own safety use only KTM approved parts and accessories KTM is not liable for damage that arises in connection with the use of other products Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle Have services carried out by a KTM dealer so that your warranty claim remains intact Contact a specialized KTM workshop supported by the KTM importer if you have any special wishes Please remember to wear a helmet protective glasses and protective clothing while driving KTM drivers are considerate drivers We wish you a lot of fun when driving ISO 9001 REG NO 12 100 6061 KTM Austria s certificate of achievement for its Quality System ISO 9001 is the
78. t parkinglight 12V 5W socket W2 1x9 5d 37 instrument lights 12V 1 2W socket W2x4 6d indicator lamps 12V 1 2W socket W2x4 6d brake rear light 12V 21 5 W socket BaY 15d flasher light 12V 10W socket Ba15s license plate illmination 12V 5W socket W2 1x9 5 d Battery maintenance free battery 12V 8Ah Steering angle 62 5 63 Wheel base 1510 10 mm 59 4 0 4 in Seat high 940 mm 37 6 in 910 mm 36 4 in Ground clearance 355 mm 14 0 in 335 mm 13 2 in Dead weight without fuel 136kg 300 Ibs 137 kg 302 Ibs Max permissible front axle load 211 kg 465 Ibs Max permissible rear axle load 335 kg 740 lbs Max permissible laden weight 350 kg 773 lbs STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSORBER 640 LC4 640 LC4 640 LC4 640 LC4 SUPERMOTO SUPERMOTO WP 0518W714 WP 0518W722 WP 0118W724 WP 0118W721 Compression adjuster 20 14 Compression adjuster 3 5 Rebound adjuster 12 14 Rebound adjuster 7 7 Spring 4 2 N mm 5 0 N mm Spring 66 260 75 260 Spring preload 6 mm 0 24in 9 mm 0 36in Spring preload 23 5 mm 0 94in 15 mm 0 6in Air chamber length 150 mm 5 9in 130 mm 5 1in Fork oil SAE 5 SAE 5 TIGHTENING TORQUES CHASSIS LC4 Collar nut front axle M16x1 5 40 Nm 30ft Ib Coll
79. t grip must be set to the ON position Now fuel may flow to carburetor In this position the tank empties down to the fuel reserve of approx 2 5 liters RES The reserve approximately 2 5 liters cannot be tapped until the twist grip is turned to the RES position Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time too CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled A WARNING A WHEN STARTING THE ENGINE MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY YOU MIGHT SLIDE OFF THE KICKSTARTER OR THE ENGINE MAY CAUSE THE KICKSTARTER TO RECOIL THEREBY CAUSING INJURIES TO FOOT AND LEG ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND WHILE DOING SO NEVER OPEN THE THROTTLE KICKSTARTING WITH INSUFFICIENT MOMENTUM AND AN OPENED THROTTLE LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL Foot brake pedal The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to
80. t the plugs together with their gaskets Tighten plug with 30 Nm and plug with 20 Nm Tighten the screw with 10 Nm Clean sealing surfaces on the frame breast pipe fill new fine screen filter with engine oil and oil rubber gasket Replace fine screen filter and screw it back in place your bare hand will do Remove oil dipstick on the clutch cover fill with 1 3 litre engine oil and attach plug again CAUTION Ust ONLY ORIGINAL KTM FINE SCREEN FILTERS USING ANOTHER FILTER BRAND CAN RESULT IN DAMAGE TO THE ENGINE F THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME YOU MUST BLEED THE OIL SYSTEM imb Ww N To facilitate bleeding of the oil system we have added a hose connection piece and a plastic hose to the set of tools Take an empty oil can 1 liter and drill a 7 mm diameter hole into the lid Screw the hose connection piece into the lid from the outside and secure it from the inside with the M8 hexagon nut Slip the plastic hose onto the hose connection piece and you will have your filling tool Fill 0 6 liters of engine oil into the can and remove the plug O next to the steering head Introduce the plastic hose into the vent hole see page 30 and fill O 6 liters of engine oil into the frame s front tube Remove plastic hose start engine and let it idle approx 20 seconds until oil escapes at the hole As soon as oil starts to escape
81. ten or replace cooling hose Remove and check thermostat opening temperature 70 C 158 F or replace it contact a KTM dealer Replace fuse and check if fan operates properly see below Contact a KTM dealer Check if fan operates properly To do this start the engine then bypass the connections to the thermoswitch bottom right radiator contact a KTM dealer TROUBLE High oil consumption CAUSE REMEDY Buckling gear ventilation hose Engine oil level too high Engine oil too thin viscosity Readjust or replace ventilation hose Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see chapter Engine oil All switched on lamps blown out Voltage regulator faulty Remove seat and check connections Have voltage regulator checked Headlight and parking light fail Blown fuse Replace fuse below the headlight mask Flasher lights brake light fan and horn fail Blown fuse Replace fuse below the headlight mask The NEUTRAL lamp is not on even though the gear is in NEUTRAL Defect indicator lamp Defect neutral switch Replace indicator lamp Connect cable to ground neutral switch must be replaced if indicator lamp lights up The battery is discharged Loose connections defect cable The ignition power consumer hasn t been switched off The battery isn t charged by the generator because Check connections and cables
82. 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 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 TROUBLE Engine fails to idle CAUSE REMEDY Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Disassemble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Engine does not rev high Carburetor fuel level because too high Float needle is dirty or worn out Float leaks The cold starting system
83. turn off the engine and mount the plug together with the gasket Let the motor run until it warms Check the oil drain plugs and the fine screen filter to make sure they are properly sealed Check the level of the motor oil Place the motorcycle on a horizontal surface main stand and wait for 5 minutes Remove the dip stick and wipe it with a piece of cloth SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN The oil level should be between the two marks on the oil dipstick however it must never rise above the MAX mark Otherwise engine oil would get into the air filter box by way of the engine venting system Add engine oil if necessary zt CAUTION 5 14 INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL DO NOT OVERFILL THE ENGINE CASE DO NOT UNDERFILL THE ENGINE CASE Afterwards check the entire oil system and motor to make sure they are properly sealed Attach the covering of the fine screen filter to the frame breast pipe NOTE Dispose of used oil properly Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter oil contaminates 1 000 000 liter water Changing oil filter Replace the oil filter when changing the engine oil Press the foot brake pedal and place a
84. usters O are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut O with 80 Nm 60 ft Ib A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE Chain maintenance For long chain life good maintenance is very important X ring chains require only modest maintenance The best way is to use lots of water but never use brushes or solvents After letting the chain dry you can use a special X ring chain spray Shell Advance Bio Chain A WARNING A No LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL CAUTION WHEN MOUNTING THE CHAIN JOINT THE CLOSED SIDE OF THE SAFETY DEVICE MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary E TE hom SX voe S 272 CHE 07 5 161718 N w A SS min 3 mm Chain wear In order to check the chain wear regard the following instruction

KTM 640LC4 Motorcycle User Manual

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