KTM 640 LC4 User Manual

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

ART.NR: 3.210.85

640 LC4 ENDURO 640 LC4 SUPERMOTO

BEDIENUNGSANLEITUNG2004

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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:



WARNING



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

Frame number

Engine number

Key number

Stamp of dealer

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.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS

MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI

TUTING THEM WITH OTHERS

. I

T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

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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

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In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

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.

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Page

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

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

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

OPERATION INSTRUMENTS ...............................................5

Clutch lever ......................................................................5

Hand decompression lever................................................5

Hand brake lever..............................................................5

Multi-functional digital speedometer ................................6

Seeting options in the display ...........................................7

Indicator lamps.................................................................8

Choke lever......................................................................8

Ignition lock .....................................................................8

Combination switch..........................................................9

Starter tip switch, emergency OFF switch, light switch .....9

Filler cap...........................................................................9

Fuel tap..........................................................................10

Shift lever .......................................................................10

Kickstarter ......................................................................10

Foot brake pedal ............................................................10

Compression damping of fork ........................................11

Rebound damping of fork ..............................................11

Compression damping of shock absorber .......................11

Rebound damping of shock absorber .............................11

Holding bars...................................................................11

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE...................................................................12

Instructions for initial operation ......................................12

Running in the LC4 models ............................................12

Accessories and payload.................................................12

DRIVING INSTRUCTIONS ..................................................13

Check the following before each start ............................13

Starting when the engine is cold.....................................14

Starting when the engine is warm or hot ........................14

What to do when the engine is „flooded“......................14

Kickstart instructions.......................................................15

Starting off .....................................................................15

Shifting, Riding...............................................................15

Braking...........................................................................15

Stopping and parkling ....................................................16

Fuel................................................................................16

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

MAINTENANCE WORK ON CHASSIS AND ENGINE ..........20

Tool set ..........................................................................20

Removing the seat..........................................................20

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

Breather plug front fork..................................................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 ring on the rear shock absorber............22

Checking chain tension...................................................23

Correct chain tension......................................................23

Chain maintenance.........................................................24

Chain wear.....................................................................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 pads........................................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 .........................................28

Dismounting and mounting the front wheel (LC4) .........29

Dismounting and mounting the front wheel

(LC4 Supermoto)............................................................29

Dismounting and mounting the rear wheel.....................30

Checking the shock absorbtion rubbers in the rear hub ..30

Tires, air pressure............................................................31

Checking spoke tension..................................................31

Changing the wheel size.................................................31

Battery ...........................................................................32

Charging the battery ......................................................32

Fuses..............................................................................33

Exchanging the headlight lamp.......................................33

Replacing the parking light bulb .....................................33

Exchanging the brake light and tail light bulb .................34

Cooling system...............................................................34

Checking the cooling liquid level ....................................35

Cleaning the air filter ......................................................35

Changing the orginal position of the clutch lever............36

Checking the oil level of the hydraulic clutch ..................36

Adjusting the throttle cable ............................................36

Checking and adjusting the chocke cable play ................37

Checking the adjustment of the hand decompression cable..37

Activating the ignition curve for low-octane fuel ............37

Adjust idling speed .........................................................37

Draining the carburetor float chamber............................38

Engine oil .......................................................................38

Checking the engine oil level..........................................38

Oil circuit........................................................................39

Oil and fine screen filter change, bleeding of the oil system..39

Changing oil filter ..........................................................40

TROUBLE SHOOTING........................................................41

CLEANING..........................................................................44

CONSERVATION FOR WINTER OPERATION ....................44

STORAGE ...........................................................................44

Re-initation after time of storage....................................44

TECHNICAL SPECIFICATIONS - CHASSIS...........................45

TECHNICAL SPECIFICATIONS - ENGINE ...........................47

HEAD WORD INDEX..........................................................48

WIRING DIAGRAM................................................APPENDIX

INDEX

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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.

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).

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").

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

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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 set-

tings 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.

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 lowfuel indicator lamp will blink). To return to the UHR mode, press the MODE button.

TEST

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

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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 longdistance 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.

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 0 and return to the previous display mode.

NOTE: To use up the reserve fuel in the tank, move the fuel cock to the RES position by hand.

10 sec

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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.



WARNING



OSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED WARNING LIGHT

FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP

– D

RIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES

– N

OT ENOUGH COOLING LIQUID IN THE SYSTEM

– T

HE 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.

Choke lever

If the choke lever 3 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 4:

= 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 .

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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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

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

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 has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch

6 to operate the electric starter.

Filler cap

The filler cap 7 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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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.

Shift lever

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

Kickstarter

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

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).

2,3,4,5

OFF ON RES

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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 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

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 0518Y737 .............12 Klicks (640 LC4)

WP 1418Y750 .............15 Klicks (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 0118Y734 .............Position 3 (640 LC4)

WP 0118Y733 .............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 0118Y734 .............Position 7 (640 LC4)

WP 0118Y733 .............Position 8 (640 LC4 Supermoto)



WARNING



HE 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.

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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

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:

– 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.

NOTE: D

URING 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



WARNING



–W

EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE

. C

LEVER

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

–D

O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE

–O

NLY 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

–T

HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY

WITH TIRES THAT HAVE THE SAME PROFILE TYPE

–N

EW 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

–D

RIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY OPERATING TEMPERATURE

. M

AXIMUM ROAD GRIP IS ASSURED WHEN

THE TIRES ARE WARM

–O

BSERVE 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

–C

HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS

–D

RIVE CAREFULLY ON UNKNOWN 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.

–N

EVER 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.



WARNING



–N

EVER 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.

– N

EVER 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

–I

F YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFACTU-

RER'S RECOMMENDED MAXIMUM PAYLOAD.

–F

ASTEN 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

625 LC4

LC4 SUPERMOTO

16:42 Z 17:42 Z

1. G 35 kmh 35 km/h

2. G 50 kmh 55 km/h

3. G 70 kmh 75 km/h

4. G 90 kmh 90 km/h

5. G 100 kmh 100 km/h

gear

ratio

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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; 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 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.

DRIVING INSTRUCTIONS

Page 15

ENGLISH

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)

6 Do not accelerate; operate starter button

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.



WARNING



–T

O AVOID INJURIES,

IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE

KICKSTARTER

–D

O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM

. E

XHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH

LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING

CAUTION

–M

AXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS

. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN

–D

ON’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 / 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

4 Switch transmission to idle (green indicator lamp N

4 lights up).

5 Do not accelerate; operate starter button

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 sparkplug.

Page 16

ENGLISH

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.



WARNING



–W

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



WARNING



EFORE 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.



WARNING



–A

VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND

ON WET OR SLIPPERY GROUND

. OTHERWISE YOU MIGHT EASILY LOSE

CONTROL OVER YOUR MOTORCYCLE

–

WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION LOCK TO POSITIONS

AND .

–D

O 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

–A

FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

CAUTION

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

EFFECT ON THE LIFE OF YOUR ENGINE

. WE RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP

. AFTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. THE ENGINE HAS REACHED ITS

OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM

–N

EVER 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

–L

ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN

LEAD TO ENGINE DAMAGE

–N

EVER 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

–I

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.



WARNING



–I

N 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

–O

N 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

–D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

Page 17

ENGLISH

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.



WARNING



–

ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE.

–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS

RUNNING

–M

OTORCYCLE 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

–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS

RUNNING

CAUTION

–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE

.OTHERWISE THE CARBURETOR

CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE

–A

LWAYS 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.

CAUTION

THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY. IF YOU

ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE STAND

, YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME

, AND YOUR

MOTORBIKE MAY FALL OVER

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

HE 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 premiumgrade 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 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE

FUEL

, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE DAMAGE WILL

OCCUR



WARNING



ASOLINE 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. IFGASOLINE 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

Page 18

ENGLISH

Page 19

ENGLISH

PERIODIC MAINTENANCE SCHEDULE

1. Service after

1000 km

2. Service after 5000 km, then

every 5000 km or

once a year

IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN

500

AINTENANCE WORK DONE BY

KTM

AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER

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 carburetor connection boots for cracks and leaks ● Check idle setting ●● Check bleeder hoses for damage and kink-free arrangement ●● Check cooling system for leaks, antifreeze protection ●● Check radiator fan for proper operation ● Check exhaust system for leaks and suspension ●● Check actuating cables for damage, smooth operation, and kink-less arrangement,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. ●● 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

●

IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER

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

●

WHEELS CHASSIS BRAKES ADD-ON-PARTS

CARBURETOR

ENGINE

640 LC4

640 LC4 SUPERMOTO

every 2 years

or 20000 km

at least

once a year

Page 20

ENGLISH

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

Check oil level ● Check brake fluid level ● Check brake pads for wear ● Check lighting system for proper operation ● Check horn for proper operation ● Lubricate and adjust actuating cables and nipples ● Bleed fork legs in regular intervals ● Remove and clean fork dust sleeves in regular intervals ● Clean and lubricate chain as necessary ●● Check chain tension ●●● Clean air filter and filter box (depending on the dirt accumulation) ● Check tire pressure and wear ● Check coolant level ● Check fuel lines for leaks ● Drain float chamber ● Check all control elements for smooth running. ● Check brake performance ●● Treat exposed metal components (except for the braking and exhaust ●

systems) with wax-based anti-corrosion agents

Treat ignition/steering lock and light switch with contact spray ● Check all screws, nuts, and hose clamps for their tight fit ●

once a yearfor cross

country use

after every

cleaning

before each

start

PERIODIC MAINTENANCE SCHEDULE

640 LC4

640 LC4 SUPERMOTO

Page 21

ENGLISH



WARNING



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

–W

HEN CLEANING THE MOTORCYCLE

, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE

, OTHERWISE WATER WILL PENETRATE THE BEARINGS,

CARBURETOR, ELECTRIC CONNECTORS ETC.

–W

HEN 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

–D

O 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.

–L

ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED

–D

ISPOSE OF OIL, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER USED OIL CONTAMINATES

1,000.000 LITERS WATER.

–

IF YOU UNFASTEN SELF-LOCKING NUTS, YOU HAVE TO REPLACE THEM BY NEW ONES.

–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 1 is located in the tool box under the right side cover.

Removing the seat

Remove the collar screws 2 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

4 engage with the seat.

Finally fasten the seat with the corresponding screw.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Page 22

ENGLISH

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

1 of the top triple clamp and turn steering stem bolt clockwise 2

until there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly rap on the triple clamp to avoid tension. Re-tighten the five clamp screws with 20 Nm.



WARNING



F 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

3 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

. I

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 4 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 dust-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



OSILICONE 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

Page 23

ENGLISH

Changing the spring preload of the shock absorber

KTM sets the shock absorber for a driver only, weighing approximately 75 kg (165 lb). If you want to take a passenger with you, of if you weigh considerably more or less than 75 kg (165 lb), you should change the spring preload accordingly

A. 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

2 changes the spring preload by

approximately 1.75 mm (0.07 in).

Loosen the locking ring

1 with the hook wrench from the tool set. Change

the spring preload with the adjusting ring

2 and retighten the locking ring.

BASIC SETTING – SPRING PRELOAD:

WP 0118Y734 .............A = 23,5mm (640 LC4)

WP 0118Y733 .............A = 22mm (640 LC4 Supermoto)

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

3 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

OT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK

ABSORBER



WARNING



HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED

NITROGEN

. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY

MAINTENANCE WORK YOURSELF

. S

EVERE INJURIES COULD BE THE RESULT.

min. 2,5 mm

Page 24

ENGLISH

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

A is tensioned. If not, correct the chain tension.



WARNING



–I

F CHAIN TENSION IS TOO GREAT

, PARTS WITHIN THE SECONDARY POWER TRANS-

MISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE

–T

OO 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

–I

N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE

Correct chain tension

Loosen collar nut 1, loosen counter nuts 2, and turn right and left adjusting screws

3 equally far. Tighten counter nuts 2.

Before tightening the wheel spindle, verify that the chain adjusters

4 are

sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. Tighten collar nut

1 with 80 Nm.



WARNING



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. 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

4 can be rotated by 180°.

CAUTION

ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

Page 25

ENGLISH

Chain maintenance

For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Motorex Chainlube Racing).



WARNING



O 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 lb) 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.

✓

15 KG

max. 272 mm

1 2 3

16 17 18

Page 26

ENGLISH

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 caliper support with Loctite 243 and tighten to 25 Nm.

BRAKE CALIPERS (LC4 SUPERMOTO): The front brake caliper

1 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

2 optimally rest

against the brake disk at any time. Secure the screws

3 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.



WARNING



RAKE 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 CAN 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

. Y

OUR MOTORCYCLE WILL 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.



WARNING



AVE 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

. T

HEREFORE

, 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

4 with

the brake pads. At its thinnest spot

A, the brake disc must not be more

than 0.4mm thinner than its nominal dimension

B. The nominal dimension

can be gaged in a location beyond the area of contact with the brake pads. Check wear in several spots.



WARNING



–B

RAKE 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

–A

SAMATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT

BY A LICENSED

KTM MECHANIC.

DOT

5.1

DOT

✓

A B

LC4

LC4 SUPERMOTO

Page 27

ENGLISH

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

Free travel at the hand brake lever may be readjusted by using adjusting screw

1. In this way, the position of the point of pressure (i.e., the

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

1 if necessary.

CAUTION

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 IN). ONLY

THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED

(TO BE RECOGNIZED BY

THE GREATER RESISTANCE OF THE HAND BRAKE LEVER

). IF THIS FREE TRAVEL IS NOT

PROVIDED

, PRESSURE WILL BUILD UP IN THE 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 2 allows you to change the basic position of the handbrake 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.



WARNING



F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN

. IN THIS CASE, CONSULT AN

AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws 4 and remove lid 5 and membrane 6. 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.



WARNING



–N

EVER USE DOT5 BRAKE FLUID! ITISBASED ON SILICONE OIL AND OF A PURPLE

COLOR

. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

–S

TORE 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

–DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT

REMOVER

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

5 mm

min. 3 mm

Page 28

ENGLISH

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.



WARNING



T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN

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

A is no longer

discernable.



WARNING



T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN

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 DESTROYING THE BRAKE DISC.

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop roller

1. 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

B 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

min.

1 mm

3-5mm

min.

1 mm

Page 29

ENGLISH

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 „MlN” marking when the vehicle is in an upright position.



WARNING



F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN

. IN THIS CASE, CONSULT AN

AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir. For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw

1. Then move the container outwards as indicated in

the illustration. Remove plug

2 with rubber boot 3 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.



WARNING



–N

EVER USE DOT 5 BRAKE FLUID! ITISBASED ON SILICONE OIL AND OF A PURPLE

COLOR

. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

RAKE 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

–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



T 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

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.

2 3

min.

1 mm

Page 30

ENGLISH

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

2 on the left fork leg. Then loosen the collar

nuts

1 before loosening the clamp screws 2 on the right fork leg.

Hold the front wheel and withdraw the wheel spindle

NOTE: The wheel spindle can be withdrawn more easily by turning it 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

1, tighten the clamping screws 2 on 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. Only after this has been accomplished, tighten the clamp screws on both fork legs with 10 Nm.



WARNING



–I

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

. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE

–A

FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS

–ITISVERY 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

4 and apply Loctite

243. Tighten the screws with 40 Nm.



WARNING



HE SCREWS 4 MUST BE SECURED WITH LOCTITE 243.

Page 31

ENGLISH

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

1, remove chain tensioner 2, hold the rear wheel

and pull out the wheel spindle

3 until the rear wheel is free but the brake

caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the rear sprocket and carefully take the rear wheel out of the swingarm.

CAUTION

–D

O NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

–A

LWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING

UPWARDS

. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

–IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND

COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE

(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.



WARNING



–I

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

. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR

OF YOUR MOTORCYCLE

–A

FTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE

PRESSURE POINT RETURNS

–ITISVERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE

, OTHER-

WISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

Checking the shock absorption rubbers in the rear hub *

LC4 models have a damped rear wheel hub. For this purpose, the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers

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.

max. 5 mm

Page 32

ENGLISH

640 LC4

front rear

Road, driver only 1,8 bar (26psi) 2,0 bar (29psi)

Road, with passenger 2,0 bar (29 psi) 2,2 bar (31psi)

640 LC4 Supermoto front rear

Road, driver only 2,0 bar (29psi) 2,2 bar (31psi)

Road, with passenger 2,2 bar (31psi) 2,4 bar (34psi)

TIRES - AIR PRESSURE

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.



WARNING



N ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE, ONLY KTM-

APPROVED TIRES MAY BE USED

. OTHER TIRES CAN HAVE A NEGATIVE EFFECT ON RIDING

PERFORMANCE

(E.G. VIBRATION AT HIGHER SPEEDS).

Approved tires for 640 LC4 (as of July 2002)

BRIDGESTONE . . . . . . . . . .TW 301/302

METZELER . . . . . . . . . . . . . .ENDURO 3, ENDURO 4, KAROO

MICHELIN . . . . . . . . . . . . . .SIRAC, T63

PIRELLI . . . . . . . . . . . . . . . .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.



WARNING



–D

O 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

–F

OR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.

–W

ORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

PERFORMS

ESPECIALLY ON WET SURFACES

–I

FAIR PRESSURE IS TOO LOW

, ABNORMAL WEAR AND OVERHEATING OF THE TIRE

CAN RESULT

–N

EW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN

TO ACHIEVE FULL GRIP

. F

OR 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

IRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE

PROPERLY RUN IN

–F

OR 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 unbalanced 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.



WARNING



–S

POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO

AN UNSTABLE HANDLING OF YOUR MOTORCYCLE

–EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING.THE

SPOKES MUST BE TENSIONED TO

4 NM.

Changing the wheel size

The preset wheel diameter (21, 19 or 17“) and the respective wheel circumference (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 will start to blink. Select the wheel diameter using the MODE button, press the SET button to confirm and save the setting.

10 sec

Page 33

ENGLISH

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.



WARNING



–I

F ELECTROLYTE (SULPHURIC ACID)

LEAKS FROM THE BATTERY, PROCEED WITH GREAT

CARE

. T

HE ELECTROLYTE CAN CAUSE SEVERE BURNS.

–I

N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER

–I

N THE CASE OF CONTACT WITH THE EYES

, THOROUGHLY RINSE EYES WITH WATER

FOR AT LEAST

MINUTES. IMMEDIATELY CONSULT A DOCTOR

–T

HE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES

VOID 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 BAR2! –N

EVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL

DESTROY THE RECTIFIER

-REGULATOR

–T

HE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT (AS

SHOWN IN THE ILLUSTRATION

), OTHERWISE ELECTROLYTE CAN ESCAPE.

BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 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

–IF THE CHARGE CONDITION CANNOT BE ESTABLISHED, THE BATTERY MAY ONLY BE

CHARGED

5 TOAMAX. OF 10 HOURS WITH 0.9 AMPERES AND A MAX. OF 14.4

VOLTS.

–A

LWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE

CHARGING UNIT ON

–W

HEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT

VENTILATION

. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING

PROCESS

–C

HARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES.

THERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES.

–A

VOID QUICK CHARGING IF POSSIBLE.

–T

O AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.

VOLT

Page 34

ENGLISH

Fuses

Fuse box A 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

(10 Ampere) protects the following power-consuming units: – ignition – starter system

Fuse

(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 A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE

ALLOWED TO BE

“REPAIRED”. AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE

ELECTRICAL INSTALLATION

Exchanging the headlight lamp

Replacing the headlight bulb Remove the headlight mask: Remove screw

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

5 out of the reflector.

Page 35

ENGLISH

Exchanging the brake light and tail light bulb

Remove the cap 1on 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 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

3 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 4 WILL BEGIN TO

BLINK WHEN THE COOLING LIQUID HAS REACHED APPROX

. 120°C (246°F), EXCEEDING

THE NORMAL OPERATING TEMPERATURE

OSSIBLE CAUSES:

–S

LOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE:

FPOSSIBLE 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

–T

OO LITTLE COOLING LIQUID IN THE SYSTEM:

ET 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. GOTOYOUR

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:

HE 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.

–

ONTINUOUS 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

OR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTI-

REEZE). 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

5; a water temperature rising up to

125°C (255°F) is admissible, without fear of problems.

Page 36

ENGLISH

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.



WARNING



–I

FPOSSIBLE, 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

–D

O NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE ESCAPING

HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS

–I

N CASE YOU GET BURNT

, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

COLD WATER RIGHT AWAY

–C

OOLANT IS TOXIC. K

EEP THE COOLANT OUT OF THE REACH OF CHILDREN

–I

N CASE COOLANT IS INGESTED

, GO SEE A DOCTOR IMMEDIATELY!

–I

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

1 and the filter box cover. Detach

retaining clip

2 and remove the air filter 3 including the filter holder 4

from the filter box.

Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid. Motorex offers environmentally-friendly products 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.

–N

EVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE, DUST

AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR

–D

UST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS

NOT MOUNTED CORRECTLY

when engine is cold

10 mm

Page 37

ENGLISH

Changing the original position of the clutch lever

The adjusting screw 1 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 counterclockwise increases the distance between the clutch lever and the handlebar.

CAUTION

ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS. O

NLY 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

2 and cover 3 together with

the rubber boot

4. 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 Kupplungsfluid 75), available from your authorized KTM workshop.

CAUTION

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. N

EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.

LWAYS USE BIODEGRADABLE HYDRAULIC OIL

SAE 10 TO FILL UP THE MASTER

CYLINDER

. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

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 5. To set the backlash, loosen the counter nut 6 and turn the adjusting screw

7 accordingly. Then, fasten the counter nut and slide

the protection cover back on. Make sure that the throttle grip will return to the idle position automatically once you let go of it. To check the correctness of this setting, start the engine, turn the handlebar left and right, in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise, you have to increase the backlash of the throttle cable.

3-5 mm

Page 38

ENGLISH

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

from the adjusting part 2. Loosen the lock nut

3 and correct the play by turning the adjusting part.

Tighten lock nut and slide protecting cap back on.

Mount the tank and seat.

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

4, loosen the counter nut and correct the adjusting screw 5

accordingly. Tighten counter nut and push back protective cover.

CAUTION

IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER

, THIS CAN RESULT IN ENGINE

DAMAGE

NOTE: No adjustment need be made to the automatic decompressor.

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

6 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 7to 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.

25 mm

4 mm

Page 39

ENGLISH

Draining the carburetor float chamber *

Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes engine malfunction. Carry out this job with the engine being cold. Close the fuel tap. Put one end of the hose

1 that leads downward behind the engine into a

collecting vessel.

Open the drain plug

2 (turning it counterclockwise) by several turns, and

drain the fuel from the float chamber. Then, retighten the drain plug and open the fuel tap.



WARNING



UEL 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

. M

ATERIALS 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.

Engine oil

Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments 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 at higher speeds. Most motorcycle engines also use the same oil to lubricate the transmission and the clutch. The JASO MA standard responds to these special requirements. 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 0°C, 32°F) or 5W/40 (for temperatures under 0°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

A of

the inspection glass. If the engine is warm, the oil level should be visible at the upper edge

B of

the inspection glass. Add engine oil if necessary.

CAUTION

–INSUFFICIENT 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

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATUR

Page 40

ENGLISH

Oil circuit

The oil pump 1 pumps the motor oil past the bypass valve 2 and through the oil filter 3. Beyond the oil filter, one of the oil lines forks off to a jet 4 that injects motor oil to the piston pin bearing and the piston head. The second oil line leads the main oil flow to the frame breast pipe

5 where the

motor oil is cooled off. Then the motor oil flows through the fine screen filter

6 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

7 and drains from there into the

crank case. A additional oil pump

8 suctions the motor oil out of the crank

case and pumps it through the oil canal

9 to the gear wheels of the 4th

and 5th gears. The motor oil reaches the oil sump via the gear wheels. The timing chain

bk also dips into the oil sump and propels motor oil upwards to

the cylinder head. The motor oil reaches the carnshaft bm and the valves through the bore

bl.

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. Otherwise, the guarantee will become void.

The engine oil change is to be carried out when the engine is still warm.



WARNING



N ENGINE HAVING BEEN RUN WARM

, AND THE ENGINE OIL IN IT IS VERY HOT - DO NOT

BURN YOURSELF

Place the motorcycle on a horizontal surface

Remove the two plugs

and

, and drain oil into a container.

CAUTION

PLUG A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.

Remove the screws and the cover

bp. Loosen the fine screen filter 6 with

an oil filter wrench and then screw it off by hand.

The screw

bq 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

bn with 30 Nm and plug bo with 20 Nm. Tighten the screw bq with

10 Nm. Clean sealing surfaces on the frame breast pipe

br, fill new fine

screen filter with engine oil, and oil rubber gasket

bs. 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

– I

F THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME, YOU

MUST BLEED THE OIL SYSTEM

1211

Page 41

ENGLISH

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 0.6 liters (0.16 US gallons) of engine oil into the can and remove the plug

1 next to the steering head. Introduce the plastic hose into the vent

hole

A, (see page 30) and fill 0.6 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

A. 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 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

–D

O NOT OVERFILL THE ENGINE CASE.

–DO NOT UNDERFILL THE ENGINE CASE

Afterwards check the entire oil system and motor to make sure they are properly sealed. Attach the covering of the fine screen filter to the frame breast pipe.

NOTE: Dispose of used oil properly! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter (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

2 and the three screws. Remove oil filter cover 3 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

4 on the connection in the oil filter cover and mount

together with a new seal

5. 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.

Page 42

ENGLISH

TROUBLE SHOOTING

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.

TROUBLE

Engine doesn’t crank.

The engine doesn't crank. The neutral indicator lamp doesn't light up.

The engine cranks only with pulled clutch lever

Engine cranks with gear engaged.

Engine cranks but doesn’t start.

CAUSE

Operating errror

Discharged battery.

Defect ignition lock or emergency OFF switch

Blown fuse safe-starting system.

Blown main fuse.

Defect safe-starting system.

Operating error

The motorcycle has been out of operation for a longer period of time. Therefore old fuel has accumulated 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 CDIunit, the pulse generator or the ignition coil has oxydized

Water in carburetor or jets blocked

Claped out side stand

Faulty side stand switch

REMEDY

Turn on the ignition, switch the gear to neutral and switch the emergency OFF switch on.

Recharge the battery and investigate the causes for discharging; contact a KTM dealer.

Check ignition lock and emergency OFF switch, contact a KTM dealer.

Replace fuse (3).

Remove seat and replace the main fuse(1). If fuse blows again contact a KTM dealer.

Contact a KTM dealer.

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 evaporate during longer periods of standstill. When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel.

Place a vessel underneath, remove the drain plug from the carburetor and open the fuel cock, – if fuel leaks out, the carburetor might need cleaning – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

Fully open the throttle when starting or exchange the spark plug, respectively

Clean and dry the spark plug or exchange it, respectively

Adjust spark plug elektrode gap to 0,9 mm (0.036 in)

Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate starter, a strong spark must be produced at the spark plug – If no spark is created exchange the spark plug. – If the new spark plug doesn't produce a spark either, dis-

connect the spark plug connector from the ignition cable,

hold it a distance of approx. 5 mm from ground and start. – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system

Remove the seat, the right side cover and the fuel tank. Clean the plug connection and treat it with contact spray

Dismount and clean carburetor

Clap up side stand

Renew side stand switch

Page 43

ENGLISH

TROUBLE

Engine fails to idle

Engine does not rev high

Engine will not reach full power

Engine overheats

CAUSE

Glogged idling jet

Oncorrect adjustment of adjusting screws on carburetor

Defective spark plug

Defective ignition system

Carburetor fuel level too high because

Float needle is dirty or worn out

Float leaks

The cold starting system is permanently 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

REMEDY

Disassemble carburetor and clean jets

Have carburetor adjusted

Replace spark plug

Have ignition system checked

Dismount carburetor and check if worn out

Replace float needle

Replace float

Adjust choke cable.

Replace membrane

Check vacuum hose and venting hose of carburetor for correct position (no kinks)

Tighten jets

Have ignition system checked

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°C (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

Page 44

ENGLISH

TROUBLE

High oil consumption

Headlight and parking light fail

Flasher lights, brake light, fan and horn fail

The NEUTRAL lamp is not on even though the gear is in NEUTRAL

The battery is discharged

No values are visible in the Tripmaster display.

No speed display.

CAUSE

Buckling gear ventilation hose

Engine oil level too high

Engine oil too thin (viscosity)

Blown fuse

Defect neutral switch.

Loose connections, defect cable.

The ignition (power consumer) hasn’t been switched off

The battery isn’t charged by the generator because

Main fuse melted through

Defective sensor cable or oxidized socket connector.

REMEDY

Readjust or replace ventilation hose

Check engine oil level when the engine is warm; correct if necessary

Use thicker engine oil; see chapter „Engine oil“

Replace fuse (5).

Replace fuse (4).

Connect cable to ground; neutral switch must be replaced if indicator lamp lights up.

Check connections and cables.

Recharge the battery according to the relevant instructions.

Remove seat and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer.

Replace the main fuse (1) under the seat

Check the sensor cable for damage and replace it if necessary. Remove the headlight mask and check the socket connector. Contact a KTM dealer.

Page 45

ENGLISH

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 CAUSE 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.

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 an air permeated tarpaulin or blanket. Do not use non air permeable materials as a possible humidity

might not be able to escape and could cause corrosion.

CAUTION

IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH

AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST

RE-INITIATION AFTER TIME OF STORAGE

– Mount the charged battery (regard polarity). – Fill up tank with fresh fuel. – Check motorcycle as before each start (see driving instructions). – Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any 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.

CLEANING

STORAGE

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



WARNING



EEP ANTI-

CORROSION AGENT FROM GETTING INTO CONTACT 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

CONSERVATION FOR WINTER OPERATION

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TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2004

640 LC4 640 LC4 Supermoto

Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power – Up Side Down 4860 MXMA Wheel travel front/rear 275 / 290 mm (11 / 11.6 in) 265 / 300 mm (10.6 / 12 in) Rear suspension Central shock absorber (WP BAVP) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, Disc brake with carbon-steel brake disc,

2-piston brake caliper floated 4-piston brake caliper Front brake disc Ø 300 mm (12 in) Ø 320 mm (12.8 in) Rear brake Disc brake with carbon-steel brake disc  220 mm (8.8 in), brake caliper floated 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. 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 Chain X – Ring 5/8 x 1/4"

Bulps headlight . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)

parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)

instrument lights . . . . . . . . LED

indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)

brake – rear light . . . . . . . . 12V 21/5 W (socket BaY15d)

flasher light . . . . . . . . . . . . 12V 10W (socket Ba15s)

license plate illmination . . . 12V 5W (socket W2,1x9,5 d) Battery maintenance-free battery 12V 8,6Ah Steering angle 62° 63° Wheel base 1510 ± 10 mm (59.4 ± 0.4 in) Seat high 925 mm (36.4 in) 910 mm (35.9 in) Ground clearance 310 mm (12.2 in) 290 mm (11.4 in) Dead weight without fuel 149kg (329 lbs) 149 kg (329 Ibs) Max. permissible front axle load

150 kg (331 lbs)

Max. permissible rear axle load

200 kg (441 lbs)

Max. permissible laden weight

350 kg (773 lbs)

640 LC4 640 LC4

SUPERMOTO

WP 0518Y737 WP 1418Y750

Compression adjuster

20 20

Rebound adjuster

12 15

Spring

4,2 N/mm 4,4 N/mm

Spring preload

5 mm (0.2 in) 28 mm (1.1 in)

Air chamber length

140 mm (5.6 in) 110 mm (4.3 in)

Fork oil

SAE 5 SAE 5

STANDARD ADJUSTMENT - FORK

640 LC4 640 LC4

SUPERMOTO

WP 0118Y734 WP 0118Y733

Compression adjuster

Rebound adjuster

Spring

66/260 70/260

Spring preload

23,5 mm(0.93 in) 16 mm(0.63 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

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Collar nut front axle M16x1.5 40 Nm Collar nut rear axle M20x1.5 80 Nm Shock absorber top M10 45 Nm Shock absorber bottom M10 45 Nm Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10 Nm Screw brake caliper front (LC4) M8 Loctite 243 + 25 Nm Screw brake caliper front (Supermoto) M10 Loctite 243 + 40 Nm Bearing bolt linkage arm/frame M12 60 Nm Collar nuts rocker arm bolts M14x1.5 100 Nm Engine mounting screw M10 45 Nm Ball joint for push rod M8 Loctite 243 + 25 Nm Sprocket screws on nuts M8 Loctite 243 + 35 Nm Hexagon nut swingarm bolt M14x1.5 100 Nm Clamping screws top triple clamp M8 20 Nm Clamping screws bottom triple clamp M8 15 Nm Clamping screws fork stubs M8 10 Nm Screws handlebar clamp M8 Loctite 243 + 20 Nm Allan head screw handle bar support M10 Loctite 243 + 20 Nm Bleeder screw oil reservoir frame M16x1.5 25 Nm Spoke nipple M4 4 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

TIGHTENING TORQUES - CHASSIS

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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 Ratio 11.7 : 1 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 Engine oil 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 4th 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 Generator 12V 200W Spark plug NGK DCPR 8 E Spark plug gap 0,9 mm Cooling system liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) Starting equipment electric starter and kickstarter

TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2004

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATURE

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 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

BASIC CARBURETOR SETTING

Type BST40-266 Main jet 152,5 Needle jet X-6 689 Idling jet 45 Jet needle 6G5 Needle clip pos. f. top 3. from top Mixt. adj. screw open 2,25

640 LC4

640 LC4 Supermoto

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Page

Accessories and payload .....................................................12

Activating the ignition curve for low-octane fuel.................37

Adjisting of free travel at the hand brake lever....................26

Adjust idling speed..............................................................37

Adjusting the throttle cable.................................................36

Battery................................................................................32

Braking ...............................................................................15

Breather plug front fork ......................................................21

Chain maintenance .............................................................24

Chain wear .........................................................................24

Changing oil filter ..............................................................40

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

Changing the wheel size .....................................................31

Charging the battery...........................................................32

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

Check the following before each start.................................13

Check the rear brake fluid level...........................................28

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

Checking and adjusting the chocke cable play ....................37

Checking chain tension .......................................................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 level ..............................................38

Checking the front brake pads ............................................27

Checking the oil level of the hydraulic clutch.......................36

Checking the rear brake pads..............................................28

Checking the shock absorbtion rubbers in the rear hub.......30

Choke lever ..........................................................................8

Cleaning .............................................................................44

Cleaning the air filter ..........................................................35

Cleaning the dust sleeves of the telescopic fork...................21

Clutch lever ..........................................................................5

Combination switch ..............................................................9

Compression damping of fork.............................................11

Compression damping of shock absorber............................11

Conservation for winter operation ......................................44

Cooling system ...................................................................34

Correct chain tension ..........................................................23

Dismounting and mounting the front wheel (LC4 Supermoto)

..29

Dismounting and mounting the front wheel (LC4)..............29

Dismounting and mounting the rear wheel .........................30

Draining the carburetor float chamber ................................38

Driving instructions .............................................................13

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

Engine oil............................................................................38

Page

Exchanging the brake light and tail light bulb......................34

Exchanging the headlight lamp ...........................................33

Filler cap ...............................................................................9

Foot brake pedal.................................................................10

Fuel ....................................................................................16

Fuel tap ..............................................................................10

Fuses ..................................................................................33

General information on KTM disc brakes ............................25

General tips and warnings for starting the motorcycle.........12

Hand brake lever ..................................................................5

Hand decompression lever ....................................................5

Head word index ................................................................48

Holding bars .......................................................................11

Ignition lock..........................................................................8

Indicator lamps .....................................................................8

Instructions for initial operation...........................................12

Kickstart instructions ...........................................................15

Kickstarter...........................................................................10

Lubricate shock absorber linkage ........................................22

Maintenance work on chassis and engine ...........................20

Multi-functional digital speedometer.....................................6

Oil and fine screen filter change, bleeding of the oil system

...39

Oil circuit ............................................................................39

Operation instruments .........................................................5

Periodic maintenance-schedule ...........................................18

Rebound damping of fork...................................................11

Rebound damping of shock absorber..................................11

Refilling the front brake fluid reservoir ................................26

Refilling the rear brake fluid reservoir..................................28

Re-initation after time of storage ........................................44

Removing the seat ..............................................................20

Replacing the parking light bulb..........................................33

Running in the LC4 models.................................................12

Seeting options in the display................................................7

Serial number locations .........................................................5

Shift lever ...........................................................................10

Shifting, Riding ...................................................................15

Starter tip switch, emergency OFF switch, light switch..........9

Starting off .........................................................................15

Starting when the engine is cold .........................................14

Starting when the engine is warm or hot ............................14

Stopping and parkling.........................................................16

Storage ...............................................................................44

Technical specifications - chassis .........................................45

Technical specifications - engine ........................................47

Tires, air pressure ................................................................31

Tool set...............................................................................20

Trouble shooting.................................................................41

What to do when the engine is „flooded“ ..........................14

Wiring diagram ........................................................Appendix

HEAD WORD INDEX

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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

8/2003 FOTO: MITTERBAUER

KTM 640 LC4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual