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KTM 640 LC4 ENDURO Motorcycle User Manual

1. 33 Replacing the parking light bulb 33 Exchanging the brake light and tail light bulb 34 Cooling SV SCC ITI 34 Checking the cooling liquid level 35 Cl anine theair TIGE a 35 Changing the orginal position of the clutch 36 Checking the oil level of the hydraulic clutch 36 Adjusting the throttle cable 36 Checking and adjusting the chocke cable 37 Checking the adjustment of the hand decompression cable 37 Activating the ignition curve for low octane fuel 37 Adjust idling Speedo era epu tats asters bd iiia 37 Draining the carburetor float 38 Salo MM LV 38 Checking the engine oil 38 eT eat TRE 39 Oil and fine screen filter change bleeding of the oil system 39 Changing oil filter iio tatio e e ea stat 40 TROUBLESHOOTING dco ute dt iiam oa tora 41 GILEA dien cU IE 44 CONSERVATION FOR WINTER OPERATION 44 STORAGE EU 44 Re initation after time of lt 44 TECHNICAL SPECIFICATIONS CHASSIS 45 TECHNICAL SPECIFICATIONS ENGIN
2. 35 Cleaning the dust sleeves of the telescopic fork 21 5 COMBINATION 9 Compression damping of 11 Compression damping of shock absorber 11 Conservation for winter operation 44 rem 34 Chall esos totes eo dI T EE 23 Dismounting and mounting the front wheel LC4 Supermoto 29 Dismounting and mounting the front wheel 29 Dismounting and mounting the rear wheel 30 Draining the carburetor float chamber 38 DEVIDSTDSEEUCHOLS osito otro i ooi Que te Gann 13 Engine number engine Ly DC v eati eot erit bees 5 he tut beo eee 38 Page Exchanging the brake light and tail light bulb 34 Exchanging the headlight lamp 33 Filler mer ne meen Nu EE 9 10 FS EEEE E EE 16 a cT 10 EE E eee tee 33 General information on KTM disc brakes 25 General tips and warnings for starting the motorcycle 12 Pand Drake I6 Vel RAE EIE 5 Hand decoim
3. 27 Changing the basic position of the handbrake lever 26 Changing the orginal position of the clutch lever 36 Changing the spring preload of the shock absorber 22 Chan sie tie wheel Size an es I REOR ERE E OR 31 Charone TCAD AUC EY Rb te D ttes 32 Chassis DUE S E aoc Ue Doku ua red 5 Check the following before each start 13 Check the rear brake fluid 28 Checking and adjusting steering head bearing 21 Checking and adjusting the chocke cable play 37 Checking chain tension o bip uS 23 Checking of brake fluid level front brake 26 Checking rubber ring on the rear shock absorber 22 Checking spoke tension 31 Checking the adjustment of the hand decompression cable 37 Checking the cooling liquid level 35 Checking the engine oil 38 Checking the front brake 5 27 Checking the oil level of the hydraulic clutch 36 Checking the rear brake 28 Checking the shock absorbtion rubbers in the rear hub 30 Gia qa cud TI 8 eade 44 Cleaning the air TIGE secours estem e ted
4. CHASSIS BRAKES ADD ON PARTS CARBURETOR ENGINE WHEELS IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2 years once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance 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 pow 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 DOO KN MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER 640 LC4 E PERIODIC MAINTENANCE SCHEDULE IU MEN TO VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC after every for cross once a year cleaning country use Check oil level before each start Check brake fluid level Check brake pads for wear Check lighting system for proper operation Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Check coolant level Check fuel lines for leaks Drain float chamb
5. 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 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 the collar nuts O before loosening the clamp screws 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 moderately with a 6 mm 0 24 in ALLAN IMBUS key while pulling Carefully remove the front wheel from the fork 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 To install the front wheel lift it into the fork position and mount the axle shaft Mount the collar nut tighten the clamping screws the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 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 on the fork a few times vigorously so that the fork legs come into alignment Onl
6. 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 LC4 The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick 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 IMPAIRING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Checking the front brake pads LC4 Supermoto The brake pads can be inspected from behind Always inspect the brake pad linings before taking off on your motorcycle They should not be thinner than 1 mm 0 04 in which is the case when the notch is no longer discernable 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 VORSICHT 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 SIGNIFICANTLY IMPARING THE BRAKING EFFECT AND DESTROY
7. Approved tires for 640 LC4 as of July 2002 BRIDGESTONE TW 301 302 METZELER ccc cc be dace ees ENDURO 3 ENDURO 4 KAROO MICHELIN SIRAC T63 PRE 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 0 08 in 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 KTM 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 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 NEW WHEELS HAVE A SMOOTH SURFACE WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP FOR THIS PURPOSE RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SP
8. 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 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 RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER 15 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 To check jack up the motorcycle on the center stand or frame until it no longer touches the ground Press the chain up approx 30 mm behind the end of the chain sliding component The chain should barely touch the swing arm when the upper chain part is tensioned If not correct the chain tension VVARNING IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY POWER TRANS MISSION CHAIN CHAIN SPROCKETS TRANSMISSION AND REAR WHEEL BEARINGS WI
9. Motorcycle ready for operation and tank full Luggage Driver with protective clothing and helmet Pay attention to running in procedure Running in the LC4 models Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding against one another for quite some time Therefore every engine needs to be broken in For this reason during its first 1000 kilometers 620 miles the engine must not be revved up to its performance limits 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 roads easy off road terrain 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 625 LC4 LC4 SUPERMOTO gear 16 42 Z 17 42 Z 35 kmh 35 km h 50 kmh 55 km h 90 kmh 90 km h 100 kmh 100 km h 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 AN WARNING AN 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 COLORED SO TH
10. Rebound damping of shock absorber 11 HEINE DAS uiui treet 11 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 12 Instructions for initial operation 12 Running in the LC4 models eb o iter aoe 12 Accessories and payload c i eei tr peni eue pe 12 DRIVING INSTRUCTIONS 13 Check the following before each start 13 Starting when the engine is 14 Starting when the engine is warm or hot 14 What to do when the engine is flooded 14 Kickstart I stEUCtlOTiS susce rd ot repete aa So tein ds 15 Statu B OF i oid brad ie ances 15 SKUDO RAINE S e osi 15 Birakin SE RF 15 Stopping att MUN MEME 16 FUB di p ee eee ee 16 PERIODIC 5 18 MAINTENANCE WORK ON CHASSIS AND ENGINE 20 TOOLSET o uisu uM IM M E 20 REMOVING the SQUE tists sates 20 Checking and adjusting steering head bearing 21 Breather plug et ie 21 Cleaning the dust sleeves of the telescopic fork 21 Changing the spring preload of the shock absorber 22 Lubricate shock absorber linkage 22 Checking rubber rin
11. 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 100 C 210 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 CONTINUOUS USE OF THE CLUTCH RIDING THE CLUTCH AT LOWER SPEEDS 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 FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZER MOTOREX ANTI FREEZE 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 125 C 255 F is admissible withou
12. 40 10W 50 ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over O C 32 F or 5W 40 for temperatures under O C 32 F Checking the engine oil level The engine oil level can be checked when the engine is cold or warm To check place the motorcycle in an upright position on a level surface center stand If the engine is cold the oil level should be visible at the lower edge Q of the inspection glass If the engine is warm the oil level should be visible at the upper edge of the inspection glass Add engine oil if necessary CAUTION NSUFFICIENT AMOUNTS OF OR LOW GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE DO NOT OVERFILL THE ENGINE CASE DO NOT UNDERFILL THE ENGINE CASE EN O J qum IN MSS 7 2 N ER See v pp 7 2 APT 2 2 EC 72777 i Ys 7 E 1 el V ze Ni II SS AS S TWO 3 E 4 a mA ex z H U Oil circuit The oil pump pumps the motor oil past the bypass valve and through the oil filter 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 p
13. 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 40 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 0 264 US gallons oil contaminates 1 000 000 liter 264 000 US gallons water Changing oil filter Replace the oil filter when changing the engine oil Press the foot brake pedal and place a 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 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 Tighten the hollow screw with seals and tighten to 15 Nm Finally start the engine and check the oil system for leakage TROUBLE SHOOTING If you let the specified mainte
14. 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 F 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 IMMEDIA TELY 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 VVARNING 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 ON SALT SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED AS WELL FIRST THE BRAKES MUST BE BRAKED CLEAN WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIP
15. ROADS OR ON UNFAMILIAR TRIALS RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES THE OPERATOR WILL BE BLINDED NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING Accessories and payload Accessory parts and baggage can significantly decrease a motorcycle s driving stability Please observe the following warnings AN WARNING AN NEVER DRIVE FASTER THAN 130 kPH 80 MPH IF YOU HAVE MOUN TED ACCESSORY PARTS ON YOUR MOTORCYCLE ACCESSORY PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE S HANDLING ESPECI ALLY IN THE MAXIMUM SPEED RANGE NEVER DRIVE FASTER THAN 130 kPH 80 MPH IF YOUR MOTORCY CLE IS LOADED WITH CASES OR OTHER BAGGAGE THEY WILL IMPAIR THE MOTORCYCLE S HANDLING AT HIGHER SPEEDS AND CAN EASILY CAUSE IT TO GO OUT OF CONTROL F YOU HAVE CASES MOUNTED DO NOT EXCEED THE MANUFACTU RER S RECOMMENDED MAXIMUM PAYLOAD FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTORCYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR WHEELS AND ON THE LEFT AND RIGHT BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE S HANDLING AND CONSIDERABLY INCREASE THE BRAKING DISTANCE ADAPT YOUR DRIVING SPEED ACCORDINGLY DRIVING INSTRUCTIONS Check the following bef
16. 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 Foot brake pedal The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work 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 cap Q By using the knob 9 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 0518Y737 20 Klicks 640 LC4 WP 1418Y750 20 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
17. 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 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 service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season TECHNICAL SPECIFICATIONS CHASSIS 640 LC4 640 LC4 SUPERMOTO 2004 po to 4 LCA Supermoto 2 piston brake caliper floated 4 piston brake caliper 0 320 mm 12 8 in Tyres front 90 90 21 120 70 17 Air press road driver only 1 8 bar 26 psi 2 0 bar 29 psi Air press road with passenger 2 0 bar 29 psi 2 2 bar 31 psi Tyres rear 130 80 18 160 60 17 Air press road driver only 2 0 bar 29 psi 2 2 bar 31 psi Air press
18. from your KTM dealer 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 184 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 overheating CAUTION THE RED TEMPERATURE WARNING LAMP FOR THE COOLING LIQUID WILL BEGIN TO BLINK WHEN THE COOLING LIQUID HAS REACHED APPROX 120 C 246 F EXCEEDING THE 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
19. 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 Checking and adjusting the choke cable play The choke lever must always have a play of approx 4 mm 0 16 in 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 Remove the seat and tank to adjust Push the choke lever all the way to the front and slide the protecting cap 9 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 L 4 m U e T RN 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 loosen the counter nut and correct the adjusting screw accordingly Tighten counter nut and push back protective cover CAUTION IF
20. switch The emergency off switch is provided for emergency situations and should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position amp ignition circuit and starter circuit are interrupted The light switch has 3 positions e Light off 2002 Parking light on O Headlight on G Use the starter tip switch to operate the electric starter 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 tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON When using the motorcycle the twist 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 HSITDNa 10 Shift lever The shift lever is mounted on the left side of the engine
21. to be checked by a KTM specialist as complete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake lever 6 CABLES Check correct setting and smooth operation of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine is cold 8 ELECTRICAL SYSTEM Check correct operation of headlamps tail lights brake lights indicators control lamps and horn while the engine is running 9 LUGGAGE If you are taking luggage with you check that this is securely fastened 10 REAR MIRROR Sit on the motorcycle and check the adjustment of the rear mirror Starting when the engine is cold Open the fuel tap 9 Switch on ignition turn ignition key into position C2 Switch on emergency OFF switch Switch transmission to idle green indicator lamp lights up Operate cold starting device choke 9 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 EN
22. 2 mode shows the speed the temperature of the cooling liquid and the trip odometer 2 To switch to the next display mode press the MODE button NJ N84 AB TRIP F The TRIP F fuel mode shows the speed the temperature of the cooling liquid and the distance traveled since reaching the low fuel mark the low fuel indicator lamp will blink To return to the UHR mode press the MODE button TRIP F ym Setting options in the display KILOMETERS OR MILES You can have the speed and distance shown in kilometers or miles in the display The display can be adapted to the respective country on long distance trips To switch from kilometers to miles switch on the ignition and press the MODE button for approx 10 seconds The km h display will switch to mph The speed and the stored distances will be converted and displayed in miles To return to kilometers proceed as described above CLOCK Switch on the ignition and change to the CLOCK mode Simultaneously press MODE and SET The numbers on the clock will start to blink Use the MODE button to set the hours and the SET button to set the minutes The press the MODE and SET buttons simultaneously NOTE 0 00 will be displayed if the clock is not supplied with electricity This can be caused by a defective fuse or a fault in the board electric system see Troubleshooting TRIP 1 The trip meter 1 runs continuously and counts up to
23. 2004 640 LC4 ENDURO 640 LC4 SUPERMOTO OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 210 85 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 CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE Please insert the serial numbers of your motorcycle in the boxes below Stamp of dealer COMSUMER 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 maintenance 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 KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERV
24. 999 9 It can be used to measure the length of a certain route on a trip or the distance between two refueling stops To return the trip meter 1 to zero switch on the ignition change to the TRIP 1 mode and press the SET button RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999 9 It can be used similarly to TRIP 1 or together with a switch available as an accessory see below for trips according to a roadbook To return the trip meter 2 to zero switch on the ignition change to the TRIP 2 mode and press the SET button NOTE A Tripmaster switch Part no 582 14 069 044 is available as an accessory and enhances the trip meter 2 functions You can correct the displayed route by increasing or decreasing in increments of 0 1 For example if you have taken the wrong road when driving according to a roadbook you can easily correct the display to correspond to the roadbook again It can also be used to change the display modes The switch is moun ted on the handlebars so that you can keep your hands on the handlebars TRIP F When the fuel level reaches the reserve mark the display will automatically switch to TRIP F and begin to count no matter which display mode was active before At the same time the fuel warning lamp will start to blink You will still have enough reserve fuel for at least 35 kilometers After refueling it will take approx 3 minutes for TRIP F to automatically reset to O and return to the pre
25. AT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE 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 VEHICLES DRIVING PROPERTIES THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE NEW WHEELS HAVE A SMOOTH SURFACE WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP FOR THIS PURPOSE RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES TILTING THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY OPERATING TEMPERATURE MAXIMUM ROAD GRIP IS ASSURED WHEN THE TIRES ARE WARM 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 CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN
26. CLE jobs see Customer Service Manual Read these operating instructions carefully before your first ride Enter the chassis engine and key numbers on page 1 Familiarize yourself with the operating elements Adjust the hand brake lever and foot brake lever to your most comfortable position Get used to handling the motorcycle on an empty parking lot or open space 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 abitily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated 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
27. DER 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 F YOU UNFASTEN SELF LOCKING NUTS YOU HAVE TO REPLACE THEM BY NEW ONES AFTER REMOVING ANY SCREWS AND NUTS SECURED WITH LOCTITE THEY MUST BE MOUNTED AND SECURED IN THE SAME MANNER SEE TECHNICAL DATA TiGHTENING TORQUES 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 the seat and push the whole seat forwards If necessary push the middle of the seat 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 ligh
28. E 47 HEAD WORD INDENXs iuit E ERR M RES 48 WIRING DIAGRAM eere APPENDIX 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 is located on the left side of the handlebar The adjusting screw is used to change the original position of the clutch lever see maintenance work on chassis and engine 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 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 Hand brake lever The hand brake lever is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw can be used to change the
29. EED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES TILTING THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN FOR REASONS OF SAFETY IT IS RECOMMENDED TO EXCHANGE THE VALVE INSERT WHENEVER A NEW TIRE IS MOUNTED 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 motorcycle 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 Changing the wheel size The preset wheel diameter 21 19 or 17 and the respective wheel circum ference 2205 2040 or 1882 mm are displayed briefly when the ignition is switched on To change the wheel diameter switch on the ignition change to the ODO mode and press the MODE and SET buttons simultaneously for approx 10 seconds The display
30. ER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BRAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS 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 NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING CAUTION CLOSE THE FUEL 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 INFORMATION ABOUT THE SIDE STAND Use your foot to p
31. GINE IS RUNNING CAUTION 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 m e A 2B T L 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 If this is not the case the battery is discharged f the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer E 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 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 al
32. IA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by SPORTMOTORCYCLE AG AUSTRIA All rights reserved IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The 640 LC4 Enduro model was designed to resist the usual wear and tear of normal use on the road and easy terrain unpaved roads The 640 LC4 Supermoto model is designed for regular on road service but not for use off of paved roads The service care and operating instructions for the engine and chassis specified in the owner s manual must be observed to ensure that the bike runs smoothly and to avoid premature wear The service work specified in the Lubrication and Maintenance Schedule must be performed and service records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specified in the owner s manual or those of an equal quality must be used in accordance with the maintenance schedule The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has be
33. ICES 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 KTM DEALER FOR INFORMATION 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 sport 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 will have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorcycle 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 out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motorcycle and should be passed on to any subsequent o
34. ING 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 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 NOTE To prevent the stop roller from turning when tightening counteract by inserting a hexagon socket wrench in hole provided for this purpose 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 L U e T NJ J 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 MIN marking when the vehicle is in an upright position 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 rear brake fluid reservoir When the brake fluid level has dropped to the MIN mark
35. L NOT LONGER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid 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 A WARNING A HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL 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 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 BRAKE DISCS Wear reduces the thickness of the brake disc in the area of contact with the brake pads A
36. LL 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 IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut loosen counter nuts and turn right and left adjusting screws equally far Tighten counter nuts Before tightening the wheel spindle verify that the chain adjusters are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut with 80 Nm 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 NOTE The large adjusting range of the chain adjusters 32mm 1 28 in allows you to use different secondary ratios in combination with the same chain length The chain adjusters can be rotated by 180 CAUTION ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED L U e T NJ max 272 mm 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 s
37. N IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE iNPLE 32 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 sunlight Charging the battery NOTE A battery charger item no 58429074000 is available from your KTM dealer You can also use the battery charger to test the battery s off load voltage startability and the generator capacity Remove the battery and check the charging level Use a voltmeter to measure the voltage between the battery poles off load voltage Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring Recharging is not required if the voltage exceeds 12 4 V Recharge if the voltage is below 12 4 V CHARGING Charge the battery for 5 to a max of 10 hours with 0 9 amperes and a max of 14 4 volts For a quick charge do not charge the battery longer than 1 hour with 4 5 amperes and a max of 14 4 volts CAUTION F THE CHARGE CONDITION CANNOT BE ESTABLISHED THE BATTERY MAY ONLY CHARGED 5 TO A MAX OF 10 HOURS WITH 0 9 AMPERES AND A MAX OF 14 4 VOLTS ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE 15 SUFFICIENT VENTILATION EXPLOSIVE GASES ARE RELEASED DURING
38. NE ROZ FUEL USING LOWER OCTANE FUEL THE IGNITION CURVE MUST BE CHANGED OTHERWISE ENGINE DAMAGE WILL OCCUR 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 MEP E PERIODIC MAINTENANCE SCHEDULE 640 LC4 640 LC4 SUPERMOTO 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 Clean oil screens and magnet of drain plug Check oil lines for damage and kink less arrangement Check and adjust spark plug replace it every 10 000 km Check and adjust valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed tight Check radiator fan for proper operation e e a _ e _ 1 Check exhaust system for leaks and suspension Check actuating cables for damage smooth operation and kink less arrangem
39. SWITCH THE IGNITION LOCK TO POSITIONS AND Do NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN CAUTION HIGH RPM RATES WHEN THE ENGINE 15 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 HE ENGINE WILL OVERSPEED DAMAGING THE VALVES N 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 120 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 MPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES
40. TACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION 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 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
41. 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 TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR Fuses Fuse box is located under the seat See Removing the seat to remove and mount the seat The fuses are numbered on the inside of the fuse box The fuses marked RES are spare fuses Main fuse 1 20 amperes protects all power consumers against short circuits Fuse 2 10 Ampere protects the following power consuming units electronic speedometer capacitor Fuse 3 10 Ampere protects the following power consuming units ignition starter system Fuse 4 10 Ampere protects the following power consuming units flasher lights brake light horn Fuse 5 10 Ampere protects the following power consuming units headlight parking light 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 CAUTION UNDER NO CIRCUMSTANCES IS STRONGER FUSE ALLOWED TO SET IN OR FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION L 4 m U 2 T w UJ Exchanging the headlight lamp Replacing the headlight bulb Remove the headlight mask Remove scr
42. THERE IS NO PLAY IN THE DECOMPRESSION LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made to the automatic decompressor Activating the ignition curve for low octane fuel If you are traveling to a country where fuel having at least 95 octane ROZ is not available you can easily activate the corresponding ignition curve A socket connector is located on a brown black cable near the digital box If the two connectors are connected to each other the ignition curve for fuel having at least 95 octane ROZ is activated If you disconnect the plug and socket connection the ignition curve for fuel having 80 94 octane ROZ is activated Although this causes the engine to lose some of its power output it prevents poor glow ignitions and engine damage CAUTION IF FUEL HAVING AT LEAST 95 OCTANE ROZ IS NOT AVAILABLE THE IGNITION CURVE FOR 80 94 OCTANE ROZ MUST BE ACTIVATED TO PREVENT ENGINE DAMAGE 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 1500 rpm 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 fl
43. USE DISTURBINGS OR LEAD TO A PREMATURE DESTRUCTION 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 sliding 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 AN WARNING AN KEEP ANTI CORROSION AGENT FROM GETTING INTO CON
44. YSTEM L U e T wW O 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 0 28 in 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 O 6 liters 0 16 US gallons of engine oil into the can and remove the plug next to the steering head Introduce the plastic hose into the vent hole Q see page 30 and fill O 6 liters 0 16 US gallons 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 begins to leak out switch off the engine mount the plug and gasket and tighten to 25 Nm 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 Checking the oil level he should be between the two marks on the inspection glass 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
45. ange the basic position of the hand brake lever Press the handbrake lever s outer end forward and at the same time turn the adjusting screw Checking of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass A WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS 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 and membrane 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 Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A NEVER USE DOT 5 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 CAUTION
46. basic position of the hand brake lever see Maintenance Multi functional digital speedometer The universal instrument is divided into 3 parts Use the MODE and SET button to change the display and the basic set tings in the display Display shows all of the information that may be of interest to you 5 display modes can be selected with the MODE button The indicator lamps provide additional information on the motorcycle s running condition Display TEST When you switch on the ignition all of the display elements will light up for 1 second for the function test WS wheel size The display will change and show the diameter of the front wheel in inches for 1 second WS wheel size Then the CLOCK mode will be displayed or the mode that was active when the ignition was switched off CLOCK You will recognize the OK display by the blinking dots between the hours and minutes It displays the speed temperature of the cooling liquid and the clock To switch to the next display mode press the MODE button m ODO The speed temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode To switch to the next display mode press the MODE button Eee TRIP 1 The TRIP 1 mode shows the speed the temperature of the cooling liquid and the trip odometer 1 To switch to the next display mode press the MODE button eee m TRIP 2 The TRIP
47. ber locations acd tip e nie Aa RS Op S 5 Shit pat 10 SURES RII ouod eerta i nte Baca b tiens 15 Starter tip switch emergency OFF switch light switch 9 Starine oe ues ax oca dit troc temer Mel 15 Starting when the engine is cold 14 Starting when the engine is warm or hot 14 Stopping and Parkins asesor eb t etat pet c Hera 16 EE eda tute 44 Technical specifications chassis 45 Technical specifications engine 47 eara crat ua end xp er saan PURA Eu 31 TOO 6 cile ned tM ised oll 20 Trouble shootin eunt po bale Dp 41 What to do when the engine is flooded 14 Wine did BEAT olen dens e rto te paddle eod Appendix 200 8 suspension fA uanvaualLiN 0103 KTM Group Partner KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at
48. caliper support with Loctite 243 and tighten to 25 Nm BRAKE CALIPERS LC4 SUPERMOTO The front brake caliper 6 has 4 brake pistons and is rigidly connected to the fork leg The rear brake caliper has one brake piston and floats which means that it is not rigidly connected to the brake caliper support The resulting lateral adjustment ensures that the brake pads optimally rest against the brake disk at any time Secure the screws of the caliper support with Loctite 243 and tighten to 40 Nm 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 A WARNING A BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC THE BRAKE PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS IF YOU USE DIFFERENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC YOUR MOTORCYCLE WIL
49. curs 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 CAUSE REMEDY Engine fails to idle Engine does not rev high Engine will not reach full power Engine overheats Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system level Carburetor fuel because too high Float needle is dirty or worn out Float leaks The cold starting system 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 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 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 Disassemble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Dismount carburetor and check if wor
50. e engine power is conveyed from the rear sprocket via 6 shock absorption rubbers 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 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 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 0 29psi Road with passenger 2 2 bar 31psi 640 LC4 Supermoto fot Road driver only Road with passenger 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 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
51. en reached No warranty will be assumed if the bike is used in races or competitions In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality ISO 9001 REG NO 12 100 6061 24 Page SERIAL NUMBER LOCATIONS cccceceeeeeeeeeeeeeeeeeeeeeneees 5 scontati 5 Engine number engine TVD6 oec 5 OPERATION INSTRUMENTS 2 5 CCE IEV a seeker penne dta fand 5 Hand decompression levet 5 Hand DrakedJe Vel a 5 Multi functional digital speedometer 6 Seeting options in the display 7 indicator Asatte soap obere 8 CHOKE TEVET Pastel addu Deus 8 LONO dore dem TE 8 Combination Gentes tatem redet 9 Starter tip switch emergency OFF switch light switch 9 Ille Cap uon dd eee eee e Ld en etree 9 Lue adposita nti lutum He 10 SITE TO 10 Kickstarter bois oppi ees iint ue 10 FOOE Drake peddi 10 Compression damping of 11 Rebound damping of fork 11 Compression damping of shock absorber 11
52. ent adjust and lubricate them Check the oil level in the master cylinder of the hydraulic clutch Clean air filter and air filter box Check cables for damage and kink less arrangement Check headlamp adjustment 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 _ e e p pow E e e _ px _ Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks 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 Check adjust steering head bearing Lubricate 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 Lubricate chain Check wheel bearings and jerk damper for play
53. er 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 AN VVARNING A ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFESSIONAL FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS 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 UN
54. ever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws and cover together with the rubber boot The oil level in the horizontal standing master cylinder should be 4 mm 0 16 in below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex Kupplungs fluid 75 available from your authorized KTM workshop CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID 36 Adjust the throttle cable When starting to turn the throttle grip you should feel an initial backlash of 3 5 mm 0 12 0 2 in If a correction is necessary start by removing the tank Slide back the protection cover To set the backlash loosen the counter nut and turn the adjusting screw 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
55. ew on the left and right Tilt the headlight mask to the front and detach from the lower fender 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 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 Mount the headlight mask Position the headlight mask such that the headlight is located under the cockpit Fit the headlight mask into the fender and mount screws 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 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 NOTE Since the bulb on the tail end is subjected to higher vibrations heavy duty bulbs are available
56. g on the rear shock absorber 22 Checking chain 23 Cortect chain tensions e peo Re de aida 23 ChairidmalttelaliC6 testes ti 24 Page General information on KTM disc brakes 25 Adjisting of free travel at the hand brake lever 26 Changing the basic position of the handbrake lever 26 Checking of brake fluid level front brake 26 Refilling the front brake fluid reservoir 26 Checking the front brake 27 Changing the basic position of the foot brake pedal 27 Check the rear brake fluid level 28 Refilling the rear brake fluid reservoir 28 Checking the rear brake pads asse co heo abe cert es 28 Dismounting and mounting the front wheel LCA 29 Dismounting and mounting the front wheel ECA SUDEMMOLO teste at tenete 29 Dismounting and mounting the rear wheel 30 Checking the shock absorbtion rubbers in the rear hub 30 TINGS 31 Checking SPOKE TENSION DRE 31 Changing the wheel Size nep eo Ee tias 31 32 Charsine the batten eet mites tendu ed 32 PUG CS ees duis ee pp a cct errat 33 Exchanging the headlight
57. iston 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 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 suctions the motor oil out of the crank case and pumps it through the oil canal 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 6 Oil and screen filter change 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 Otherwi
58. lamp Loctite 243 20 Nm 25 Nm i Nm Other screws on chassis M6 10 Nm M8 25 Nm M10 45 Nm Other collar nuts on chassis M6 15 Nm M8 30 Nm M10 50 Nm TECHNICAL DATA ENGINE 640 LC4 640 LC4 Supermoto 2004 Engine 640 LC4 Design Liquid cooled single cylinder 4 stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore Stroke 101 78 mm Fuel unleaded premium gasoline with at least RON 95 USA Premium RON 91 RON 80 94 for other ignition curve 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 32 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 aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication two Eaton oilpumps see bellow Engine oil quantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 31 79 teeth Clutch multi disc clutch in oil bath hydraulically operated Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 Ath 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN 4K5 Ignition timing adjustment to max 38 BTDC at 6000 rpm 12V 200W Spark plug NGK DCPR 8 E Spark plug gap 0 9 mm Cooling system liquid cooled pe
59. light Blown fuse Replace fuse 4 fan and horn fail The NEUTRAL lamp is not Defect neutral switch Connect cable to ground neutral switch must be replaced if on even though the gear is indicator lamp lights up in NEUTRAL Loose connections defect cable Check connections and cables The battery is discharged The ignition power consumer Recharge the battery according to the relevant instructions hasn t been switched off The battery isn t charged by the Remove seat and check voltage regulator connections voltage generator because regulator and generator should be checked by a KTM dealer No values are visible in the Main fuse melted through Replace the main fuse 1 under the seat Tripmaster display No speed display Defective sensor cable or oxidized Check the sensor cable for damage and replace it if necessary socket connector Remove the headlight mask and check the socket connector Contact 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 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 CA
60. liquid reaches 120 C 248 This warning light has no function This warning light has no function This indicator lamp has no function amp amp amp Choke lever If the choke lever 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 Ignition lock with 3 switch positions Switch positions of ignition lock O Ignition off engine can t be started Ignition on engine can be started Ignition off handlebar blocked To switch the ignition to position amp turn the ignition key 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 and Combination switch The rocker switch LIGHTS Q actuates the high beam or low beam D High beam light ZO Low beam light D The light signal high beam is actuated with button o The indicator switch amp returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher be The horn is sounded with button ar U 2 9 Starter tip switch emergency OFF tip switch light
61. n 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 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 Refill cooling liquid see maintenace work check cooling system for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Shorten or replace cooling hose Remove and check thermostat opening temperature 70 157 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 CAUSE REMEDY High oil consumption Buckling gear ventilation hose Readjust or replace ventilation hose Engine oil level too high Check engine oil level when the engine is warm correct if necessary Engine oil too thin viscosity Use thicker engine oil see chapter Engine oil Headlight and parking light Replace fuse 5 fail Flasher lights brake
62. nance work on your motorcycle be carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the trouble shooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by oneself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine doesn t crank The engine doesn t crank The neutral indicator lamp doesn t light up The engine cranks only with pulled clutch lever Engine cranks engaged Engine cranks but doesn t Operating errror Discharged battery Defect ignition lock or emergency OFF switch Blown fuse safe starting system Blown main fuse Turn on the ignition switch the gear to neutral and switch the emergency OFF switch on Recharge the battery and investigate the causes for dischar ging contact a KTM dealer Check ignition lock and emergency OFF switch contact a KTM dealer Replace fuse 3 Remove seat and replace the main fuse 1 If fuse blows again contact a KTM dealer Defect safe starting system Contact a KTM dealer 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 generato
63. oat chamber causes engine malfunction Carry out this job with the engine being cold Close the fuel tap Put one end of the hose 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 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 HSIPTDNa 38 Engine oil Automobile engine oil used to be used for four stroke motorcycles before JASO T903 MA there were separate motorcycle specifications Different technical develop ments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing intervals motorcycle engines require a higher power output TEMPERATUR at higher speeds Most motorcycle engines also use the same oil to lubricate 0 C the transmission and the clutch The JASO MA standard responds to these 32 F special requirements Only use fully synthetic engine oils that meet the JASO MA quality require 5W
64. olvents After letting the chain dry you can use a special X ring chain spray Motorex Chainlube Racing 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 Chain wear In order to check the chain wear regard the following instructions Shift the gear into idling and pull the upper chain strand with approx 10 15 kilogramm 33 16 upwards see figure Now one 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 88 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 LC4 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
65. ore each start When you start the motorcycle must be in perfect mechanical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start E i ait 1 ff AV srl 1 e ILE Lu malc hr U uim TY A LJ WI 2 m M z 1 1 j The following checks should be performed 1 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks 3 CHAIN A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear of chain and chain wheels 4 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 deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir 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
66. ptressiof eVel 5 Head word Index sssaaa ae eta 48 TR 11 PE MMOMMOCK a E 8 REN ET DH CENE 8 Instructions for initial 12 IIS UH OHOFEIS ees eausa o rabbia 15 occi cette 10 Lubricate shock absorber linkage 22 Maintenance work on chassis and engine 20 Multi functional digital 6 Oil and fine screen filter change bleeding of the oil system 39 ERU EO ner en eee ere ore 39 Operatiominstrumenls cao t ie eem uet tiat 5 Periodic maintenance schedule 18 Rebound damping of fork 11 Rebound damping of shock 11 Refilling the front brake fluid reservoir 26 Refilling the rear brake fluid 28 Re initation after time of storage 44 Removing the m 20 Replacing the parking light 6 33 Running in the LC4 nnee 12 Seeting options in the 7 Serial num
67. r or the ignition coil has oxydized Water in carburetor or jets blocked Claped out side stand Faulty side stand switch with gear Defect safe starting system Contact a KTM dealer Open fuel tap tank fuel you did not use choke Pay attention to starting off information see driving instructions The easily inflammable components of the new fuels evapo rate during longer periods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off when the float chamber is filled with new fuel Place a vessel underneath remove the drain plug from the carburetor and open the fuel cock if fuel leaks out the carburetor might need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap Fully open the throttle when starting or exchange the spark plug respectively Clean and dry the spark plug or exchange it respectively Adjust spark plug elektrode gap to 0 9 mm 0 036 in Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate starter a strong spark must be produced at the spark plug f no spark is created exchange the spark plug f 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 oc
68. rake 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 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 F THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE MOTOREX LONG THERM 2000 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 push the rear wheel forwards so that the chain tensioners lie on the tension screws VVARNING A F 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 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 T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE OTHER WISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED iNPLE UJ Checking the shock absorption rubbers in the rear hub LC4 models have a damped rear wheel hub For this purpose th
69. 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 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 turning 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 for example the engine stalls at an intersection simply pull the clutch lever and start You do not need to shift into the neutral position AN WARNING A 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
70. rmanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter 40 antifreeze 60 water atleast 25 13 F Starting equipment electric starter and kickstarter ENGLISH A N BASIC CARBURETOR SETTING 640 LC4 JASO T903 MA 640 LCA Supermoto Type BST40 266 TEMPERATURE Main jet 152 5 0 C Needle jet X 6 689 32 F idling jet Jet needle 6G5 5W 40 10W 50 Needle clip pos f top 3 from top Mixt adj screw open 2 25 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over O C 32 F or 5W 40 for temperatures under O C 32 F HEAD WORD INDEX Page Accessories and payload 12 Activating the ignition curve for low octane fuel 37 Adjisting of free travel at the hand brake lever 26 37 Adjusting the throttle 36 suni MMC 32 TS 15 Breather plug front fork oe taut pes 21 Chainimalntelalie ento cri pter ermita os 24 CBS 24 Changing Oil TEM Sep editt odes 40 Changing the basic position of the foot brake pedal
71. road with passenger 2 2 bar 31 psi 2 4 bar 34 psi Fuel tank capacity 12 liter 3 1 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 16 42t 17 42t X Ring 5 8 x 1 4 instrument lights indicator lamps brake rear light flasher light 12V 1 2W socket W2x4 6d 12V 21 5 W socket BaY15d 12V 10W socket 155 12V 5W socket W2 1x9 5 d headlight H4 12V 60 55W socket P43t license plate illmination maintenance free battery 12V 8 6Ah Steering angle 62 Wheel base parking light 12V 5W socket W2 1x9 5d Seat high 310 mm 12 2 in Max permissible front axle load Max permissible rear axle load Max permissible laden weight STANDARD ADJUSTMENT FORK 640 LC4 640 LC4 SUPERMOTO WP 1418Y750 20 15 4 4 N mm 28 mm 1 1 in 110 mm 4 3 in Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil 925 mm 36 4 in Dead weight without fuel 149kg 329 Ibs 63 1510 10 mm 59 4 0 4 in 910 mm 35 9 in 290 mm 11 4 in 149 kg 329 Ibs 150 kg 331 Ibs 200 kg 441 Ibs 350 kg 773 165 STANDARD ADJUSTMENT SHOCK ABSORBER 640 LC4 640 LC4 SUPERMOTO WP 0118Y733 70 260 Compression adjuster Rebound adjuster Spring Spring preload TIGHTENING TORQUES CHASSIS Collar nut front axle M16x1 5 40 Nm ll joint for push rod Sprocket screws on nuts M 8 Hexagon nut swingarm bolt M14x1 5 100 Nm 8 20 Nm Screws handlebar c
72. se the guarantee will become void The engine oil change is to be carried out when the engine is still warm A WARNING A 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 D and drain oil into a container CAUTION PLUG MUST NOT BE REMOVED THIS IS PART OF THE BY PASS VALVE Remove the screws 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 remount 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 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 0 34 US gallons engine oil and attach plug again CAUTION USE 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 S
73. so 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 C Switch on emergency OFF switch Switch transmission to idle green indicator lamp lights up Do not accelerate operate starter button Take the motorcycle off of the main stand or side stand What to do when the engine is flooded The throttle must be fully opened when starting If necessary change spark plug Kickstart instructions Be sure to kick up the side stand before you start the engine to avoid any damage Start as described above then push the kickstarter hard ALL THE WAY AN 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 CAUTION BEFORE YOU ACTUATE THE KICKSTARTER BE SURE TO KICK UP THE SIDE STAND Starting off Pull the clutch lever Put the engine into first gear slowly
74. t fear of problems DM 10 mm when engine is cold 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 WARNING A F POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS N CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN IN CASE COOLANT IS INGESTED GO SEE A DOCTOR IMMEDIATELY F COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR Cleaning the air filter It is very important for the engine s life expectancy to clean the air filter regularly To clean the air filter remove screws and the filter box cover Detach retaining clip and remove the air filter including the filter holder from the filter box Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid Motorex offers environmentally friendly produc
75. t 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 WARNING 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 AS 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 LC4 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 When you press the hand brake lever forwards you should have at least 3 mm 0 12 in free travel Turn the adjusting screw if necessary CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST LEAST BE 3 MM 0 12 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Changing the basic position of the handbrake lever LC4 Supermoto The adjusting screw allows you to ch
76. t protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray Then push dust protection bellows into the outer tubes by hand WARNING A NO SILICONE OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE 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 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 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 0118 734 A 23 5mm 640 LC4 WP 0118 733 22 640 LC4 Supermoto 22 Lubricating the shock absorber linkage The bearings in the rocker arm must be greased Motorex Long Therm 2000 in regular intervals For this purpose a grease nipple
77. tly rap on the triple clamp to avoid tension Re tighten the five clamp screws with 20 Nm A WARNING 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 Bleeder screws for telescopic fork After every 5 hours of use for competitive racing slacken the breather plugs a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on street it will be enough to have this job performed in the course of the periodical maintenance service CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF YOUR FORK IS LEAKING IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED Cleaning the dust sleeves of the telescopic fork The dust protection bellows are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dus
78. ts for professional oil filter maintenance Motorex Bio Dirt Remover Motorex Liquid Bio Power 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 highgrade 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 NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS NOT MOUNTED CORRECTLY Changing the original position of the clutch lever The adjusting screw can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclock wise increases the distance between the clutch l
79. ush 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 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 NOTE REGARDING THE CENTER STAND is available as an accessory We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible a press main stand to 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 BY 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 Fuel In the condition at delivery the LC4 engine requires unleaded premium grade fuel with at least 95 octane ROZ If using lower octane fuel it is easy to change over to the pre programmed ignition curve for 80 94 octane ROZ see activating the ignition curve for low octane fuel CAUTION USE UNLEADED PREMIUM GRADE 95 OCTA
80. vious display mode NOTE To use up the reserve fuel in the tank move the fuel cock to the RES position by hand U 2 7 MODE ON INN 120 C 248 EBENE 110 C 230 F re bs 100 C 212 F 70 C 158 F HM 60 C 140 F BMW 50 122 F EN 40 C 104 F TRIP Cooling liquid temperature display The temperature display is shown in 7 bars The more bars that light up the hotter the cooling liquid When the lowest bar lights up the cooling liquid has reached a temperature of approx 40 C 104 F When the upper bar lights up 120 C 248 F all of the bars will start to blink and the red warning lamp will light up A WARNING A POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE CAUSING THE RED WARNING LIGHT FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES NOT ENOUGH COOLING LIQUID IN THE SYSTEM THE VENTILATOR ON THE RADIATOR IS NOT RUNNING IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on NOTE The indicator lamp will blink slower when a blinker is broken e The green indicator lamp will light up when the gearbox is in an idling position The blue indicator lamp will light up when the high beams are switched on The red warning lamp will start to blink when the cooling
81. will go turn it back counter clockwise by as many clicks as are specified for the relevant type of fork WP 0518Y737 12 Klicks 640 LC4 WP 1418Y750 15 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 0118Y734 Position 3 640 LC4 WP 0118Y733 Position 4 6540 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 0118 734 Position 7 640 LC4 WP 0118Y733 Position 8 6540 LC4 Supermoto A WARNING A 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 L 4 m U e T mah E GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHI
82. will start to blink Select the wheel diameter using the MODE button press the SET button to confirm and save the setting Battery The battery is located under the seat and is maintenance free 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 Remove screws and swing retaining bracket and voltage regulator out of the way First disconnect the negative and then the positive pole of the battery Remove battery When replacing connect first the positive and then the negative pole A WARNING A F ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER N 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 CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY DEFECTIVE 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 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOW
83. wner in case you decide to sell it We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chassis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer For your own safety use KTM approved parts and accessories only 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 To ensure that all work to your KTM is performed properly and to avoid warranty conflicts KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer Off road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others We wish you a lot of fun when driving KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTR
84. y after this has been accomplished tighten the clamp screws on both fork legs with 10 Nm WARNING A F 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 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 T 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 However the brake caliper has first to be removed To remove the front brake caliper remove both screws 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 40 Nm A WARNING A THE SCREWS MUST BE SECURED WITH LOCTITE 243 L 4 m U 2 T NJ Xo Dismounting and mounting the rear wheel To remove the rear wheel jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Loosen the collar nut remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the b
85. 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 and add brake fluid DOT 5 1 Motorex Brake Fluid DOT 5 1 up to the MAX 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 VVARNING A NEVER USE DOT 5 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 HSIPTDNa 28 A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the 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 WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM 0 04 IN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION

KTM 640 LC4 ENDURO Motorcycle User Manual

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