KTM 640 LC4 User Manual

OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES

ART. NR. 3.211.47

640 LC4 ENDURO 640 LC4 SUPERMOTO

BEDIENUNGSANLEITUNG2005

ENGLISH

IMPORTANT »

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

Stamp of dealer

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly. In your own interest, please pay particular attention to notices that are marked as follows:

– IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB!

– IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR-

CYCLE’S TRAFFIC SAFETY!

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 inopera-

tive by any person.

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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 owner 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, AUSTRIA

Attachments: 1 spare parts manual chassis & engine

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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 been 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.

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INDEX »

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ignition lock with 3 switch positions . . . . . . . . . . . . . .6

Multi-functional digital speedometer . . . . . . . . . . . . .7

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Setting options in the display . . . . . . . . . . . . . . . . . . .8

Cooling liquid temperature display . . . . . . . . . . . . . . .8

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .10

Starter tip switch, emergency OFF tip switch, light switch

.10

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Compression damping of fork . . . . . . . . . . . . . . . . .12

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .12

Compression damping of shock absorber . . . . . . . . . .12

Rebound damping of shock absorber . . . . . . . . . . . . .12

Holding bars (LC4 Enduro) . . . . . . . . . . . . . . . . . . . .12

Grip (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . .12

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Instructions for initial operation . . . . . . . . . . . . . . . .13

Running in the LC4 models . . . . . . . . . . . . . . . . . . .13

Accessories and payload . . . . . . . . . . . . . . . . . . . . .13

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .14

Check the following before each start . . . . . . . . . . . .14

Starting when the engine is cold . . . . . . . . . . . . . . . .15

Starting when the engine is warm or hot . . . . . . . . . .15

What to do when the engine is „flooded” . . . . . . . . . .15

Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . .16

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .18

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .20

Tool set (LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . .20

Removing the seat (LC4 Enduro) . . . . . . . . . . . . . . . .20

Removal of seat (LC4 Supermoto) . . . . . . . . . . . . . . .21

Tool set (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . .21

Checking and adjusting steering head bearing . . . . . .21

Bleeder screws for telescopic fork . . . . . . . . . . . . . . .22

Cleaning the dust sleeves of the telescopic fork . . . . .22

Changing the spring preload of the shock absorber . . .23

Lubricating the shock absorber linkage . . . . . . . . . . .23

Checking rubber ring on the WP rear shock absorber . .23

Checking chain tension . . . . . . . . . . . . . . . . . . . . . .24

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .24

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .25

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

General informations about KTM disc brakes . . . . . . .26

Page

Adjusting of free travel at the hand brake lever (LC4 Enduro)

.27 Changing the basic position of the handbrake lever

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Checking of brake fluid level - front brake . . . . . . . . .27

Refilling the front brake fluid reservoir . . . . . . . . . . .27

Checking the front brake pads (LC4 Enduro) . . . . . . .28

Checking the front brake pads (LC4 Supermoto) . . . . .28

Changing the basic position of the foot brake pedal . .28

Checking rear brake fluid level . . . . . . . . . . . . . . . . .29

Checking the rear brake pads . . . . . . . . . . . . . . . . . .29

Dismounting and mounting the front wheel (LC4 Enduro)

.30 Dismounting and mounting the front wheel

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Dismounting and mounting the rear wheel . . . . . . . . .31

Checking the shock absorption rubbers in the rear hub

.31

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .32

Changing the wheel size . . . . . . . . . . . . . . . . . . . . . .32

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .33

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Exchanging the brake light and tail light bulb

(LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Exchanging the brake light and tail light bulb (LC4

Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Exchanging the headlight lamp (LC4 Enduro) . . . . . . .35

Replacing the parking-light bulb (LC4 Enduro) . . . . . .35

Exchanging the headlight lamp (LC4 Supermoto) . . . .36

Replacing the parking-light bulb (LC4 Supermoto) . . .36

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Checking the cooling liquid level . . . . . . . . . . . . . . .37

Cleaning the air filter (LC4 Enduro) . . . . . . . . . . . . . .38

Cleaning of air filter (LC4 Supermoto) . . . . . . . . . . . .38

Exhaust system (LC4 Supermoto) . . . . . . . . . . . . . . .39

Changing the original position of the clutch lever . . . .39

Checking the oil level of the hydraulic clutch . . . . . . .39

Checking and adjusting the choke cable play . . . . . . .40

Checking the adjustment of the hand decompression

cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Adjust the throttle cable . . . . . . . . . . . . . . . . . . . . .40

Activating the ignition curve for low-octane fuel . . . . .41

Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . .41

Draining the carburetor float chamber . . . . . . . . . . . .41

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Checking the engine oil level . . . . . . . . . . . . . . . . . .42

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Oil and screen filter change, bleeding of the oil system

.43

Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .44

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .45

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .48

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Re-initiation after time of storage . . . . . . . . . . . . . . .48

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . .49

TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . .51

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .52

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix

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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.

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OPERATION INSTRUMENTS »

Clutch lever

The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically.

Hand decompression lever

The hand decompression lever [2] 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 [3] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see "Maintenance").

Choke lever

If the choke lever [4] 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 [5]:

= Ignition off, (engine can't be started)

= Ignition on, (engine can be started)

= Ignition off, handlebar blocked

To switch the ignition to position turn the ignition key to position 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 .

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OPERATION INSTRUMENTS »

Multi-functional digital speedometer

The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display. Display [2] 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 [3] provide additional information on the motorcycle's running condition.

TEST

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

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.

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.

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.

TRIP 2 The TRIP 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.

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.

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OPERATION INSTRUMENTS »

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 [1] 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 [1] and SET [2]. 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 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 mounted on the handlebars so that you can keep your hands on the handlebars.

10 sec

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OPERATION INSTRUMENTS »

Cooling liquid temperature display

The temperature display [1] 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 [2] will light up.

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 TEM-

PERATURES – 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.

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 liquid reaches 120°C (248°F).

This warning light has no function.

This indicator lamp has no function.

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

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OPERATION INSTRUMENTS »

Combination switch

The rocker switch LIGHTS [1] actuates the high beam or low beam.

= High-beam light

= Low-beam light

The light signal (high beam) is actuated with button [2].

The indicator switch [3] returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher.

The horn is sounded with button [4].

Starter tip switch, emergency OFF tip switch, light switch

The emergency off switch [5] 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 (ignition circuit and starter circuit are interrupted).

The light switch [6] has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch [7] to operate the electric starter.

Filler cap

The filler cap [8] 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.

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OPERATION INSTRUMENTS »

2,3,4,5

OFF ON RES

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 posi-

tion. 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.

Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

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).

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OPERATION INSTRUMENTS »

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 [A]. By using the knob [1] (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 05187A02 ........................20 clicks (640 LC4)

WP 14187A07 ........................15 clicks (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 [2] (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

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 05187A02 ........................12 clicks (640 LC4)

WP 14187A07 ........................15 clicks (640 LC4 Supermoto)

Compression damping of shock absorber

With the knob [3] 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 01187A03 ........................position 3 (640 LC4)

WP 01187A02 ........................position 4 (640 LC4 Supermoto)

Rebound damping of shock absorber

With the setting wheel [4] 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 01187A03 ........................position 7 (640 LC4)

WP 01187A02 ........................position 8 (640 LC4 Supermoto)

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 (LC4 Enduro)

The passenger can hold on to the holding bars on the rear end of the vehicle.

Grip (LC4 Supermoto)

The passenger grip is located in the center of the seat.

– 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 THAT 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 DRIV-

ERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. – 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 PUR-

POSE, 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 HAZ-

ARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE. – CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS

AND YOUR DRIVING SKILLS. – DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRI-

ALS. – 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.

– 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. – NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOU HAVE

MOUNTED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY

PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE'S HAN-

DLING, ESPECIALLY IN THE MAXIMUM SPEED RANGE. – NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOUR MOTOR-

CYCLE 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 – IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFAC-

TURER'S RECOMMENDED MAXIMUM PAYLOAD. – FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTOR-

CYCLE 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. – NEVER EXCEED THE MAXIMUM PERMISSIBLE LADEN WEIGHT

AND THE AXLE WEIGHTS. THE MAXIMUM PERMISSIBLE LADEN

WEIGHT IS MADE UP OF THE FOLLOWING COMPONENTS:

– MOTORCYCLE READY FOR OPERATION AND TANK FULL

– LUGGAGE

– DRIVER WITH PROTECTIVE CLOTHING AND HELMET.

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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION OF

VEHICLE 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 abi-

tily 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 manu-

facturers can impair the safety of the motorcycle. – Motorcycles are sensitive to changes in the weight

distribution. Read the section on "Accessories and payload“

when carrying luggage. – 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.

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.

LC4 Enduro

LC4 Supermoto

16:42 Z 17:42 Z

1. G 35 km/h 35 km/h

2. G 50 km/h 55 km/h

3. G 70 km/h 75 km/h

4. G 90 km/h 90 km/h

5. G 100 km/h 100 km/h

gear

ratio

ENGLISH

DRIVING INSTRUCTIONS »

Check the following before 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.

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.

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 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.

ENGLISH

DRIVING INSTRUCTIONS »

Starting when the engine is cold

1 Open the fuel tap [1] 2 Switch on ignition (turn ignition key [2] into position ). 3 Switch on emergency OFF switch [3]. 4 Switch transmission to idle (green indicator lamp N [4] lights up). 5 Operate cold starting device (choke) [5]. 6 Do not accelerate; operate starter button [6]. 7 If the engine starts, push the choke lever back a little bit, as soon as the

engine runs unevenly.

8 Take the motorcycle off of the main stand or side stand.

– TO AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE

KICKSTARTER.

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM.

EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

– MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN.

– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE

WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM.

If the engine is does not crank when you actuate the starter tip switch:

– the transmission is switched to idle – Check if the emergency OFF switch is on – Check if the ignition is on – the headlight is on.

– If this is not the case, the battery is discharged – If the lights are on, proceed as described in the „Trouble-shooting“ section or contact a KTM dealer.

If the engine cranks but does not start, when you actuate the starter tip switch:

– Check if the fuel tap is open – Check if the choke lever has been operated – Check if sufficient fuel is in the tank – If 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 ENDURO / LC4 SUPERMOTO: This motorcycle is equipped with a safety starter system. The engine can only be started when the transmission is switched to idle or the clutch lever is pulled, respectively. Motorcycles with side stands are also equipped with a safety starting system. If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop.

Starting when the engine is warm or hot

1 Open the fuel tap [1] 2 Switch on ignition (turn ignition key [2] into position ). 3 Switch on emergency OFF switch [3]. 4 Switch transmission to idle (green indicator lamp N [4] lights up). 5 Do not accelerate; operate starter button [6]. 6 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.

ENGLISH

DRIVING INSTRUCTIONS »

– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN

TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

– LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH

CAN LEAD TO ENGINE DAMAGE.

– NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER.

OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR.

– THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT

TEMPERATURE HAS REACHED 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

-IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY, SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE.

- CAUTION SCALDING HAZARD! - AND CHECK THE COOLING LIQUID LEVEL. DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.

– IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK

THAT THE ENGINE FASTENING BOLTS ARE TIGHT.

– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER.

Braking

Close throttle and apply the hand and foot brakes at the same time. When driving on sandy, wet or slippery ground use mainly the rear wheel brake. Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. When driving downhill, use the braking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to brake so much and the brakes will not overheat.

– 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

CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL.

– DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS

AND BRAKE DISCS.

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.

– 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.

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 release the clutch lever and open throttle at the same time.

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.

– AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS

AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EAS-

ILY LOSE CONTROL OVER YOUR MOTORCYCLE. – WHILE RIDING YOUR MOTORCYCLE, NEVER 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.

ENGLISH

DRIVING INSTRUCTIONS »

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.

– 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 RUN-

NING. 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 HAZ-

ARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE

ENGINE IS RUNNING.

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CAR-

BURETOR 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 push the side stand forward as far as possible, and lean your motorcycle to the side. Make sure that your motorcycle is standing safely on solid ground. Just in case, you can also put in a gear.

– PARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD

GROUND, LEVEL SURFACE) AND CAN’T TIP OVER.

– THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE

ONLY. IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE STAND, YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME, AND YOUR MOTORBIKE MAY FALL OVER.

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 illus-

trated (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely.

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).

USE UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE DAMAGE WILL OCCUR.

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.).

35 mm

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