KTM 640 Universal 2003 Owner's manual

MANUALE D’USO

OWNER’S MANUAL

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

BEDIENUNGSANLEITUNG

640 LC4 ENDURO 640 LC4 SUPERMOTO

2003

Art.Nr. 3.210.56 8/2002

ENGLISH

1

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 mainten-

ance, repair or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser
or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or rendered

inoperative by any person.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

AG

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

,

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

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

,

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI

-

TUTING THEM WITH OTHERS

. I

TSHALL 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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2

Introduction

We would like to congratulate you on your purchase of a KTM motorcycle.

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring
you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

Before you go for your first ride, be sure to read this manual carefully and thoroughly in
order to familiarize yourself with how to operate your new motorcycle and with its
characteristics, even if this means that you will have to dedicate some of your valuable
time to this task. Only by doing so will you learn how to tune your motorcycle to your
specific needs and how to protect yourself against injury. Besides, this manual contains
important information on motorcycle maintenance. At the time this manual was typeset,

it was up-to-date with the latest state of this production series. It cannot be completely
ruled out, however, that minor discrepancies may exist resulting from further design
upgrades of these motorcycles.This manual is an important part of your motorcycle and
should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance
work on the chassis and engine" must be performed. If maintenance work should
become necessary during a competition it should be performed by a trained mechanic.
KTM strongly recommends that all service work to your KTM should be performed by a
qualified KTM dealer.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable
for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance
intervals. Heeding these guidelines will significantly increase the life of your motorcycle.
To ensure that all work to your KTM is performed properly and to avoid warranty
conflicts, KTM recommends that you always have your KTM serviced by a recognized
and qualified KTM dealer.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to
enjoy it to the full. It may, however, involve potential problems for the environment or
lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle
is used responsibly. To safeguard the future of motorcycle sports, make sure that you use
the motorcycle in accordance with the law, show that you are environmentally conscious
and respect the rights of others.

We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

©

by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3

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 models are designed to withstand normal use on roads and
easy terrain (unpaved roads).

The 640 LC4 Supermoto models are not suitable 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.

ENGLISH

4

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

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

Page

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

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

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

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

Checking of brake fluid level - front brake......................26

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

Checking the front brake pads........................................26

Changing the basic position of the foot brake pedal .......27

Check the rear brake fluid level ......................................27

Refilling the rear brake fluid reservoir .............................27

Checking the rear brake pads .........................................27

Dismounting and mounting the front wheel (LC4) .........28

Dismounting and mounting the front wheel

(LC4 Supermoto)............................................................28

Dismounting and mounting the rear wheel.....................29

Checking the shock absorbtion rubbers in the rear hub ..29

Tires, air pressure............................................................30

Checking spoke tension..................................................30

Changing the wheel size.................................................30

Battery ...........................................................................31

Charging the battery ......................................................31

Fuses..............................................................................32

Exchanging the headlight lamp.......................................32

Replacing the parking light bulb .....................................32

Exchanging the brake light and tail light bulb .................33

Cooling system...............................................................33

Checking the cooling liquid level ....................................34

Cleaning the air filter ......................................................34

Adjusting the throttle cable ............................................35

Checking the oil level of the hydraulic clutch ..................35

Changing the orginal position of the clutch lever............35

Checking and adjusting the chocke cable play ................36

Checking the adjustment of the hand decompression cable..36

Adjust idling speed .........................................................36

Draining the carburetor float chamber............................37

Engine oil .......................................................................37

Checking the engine oil level..........................................37

Oil circuit........................................................................38

Oil and fine screen filter change, bleeding of the oil system..38

Changing oil filter ..........................................................39

TROUBLE SHOOTING........................................................40

CLEANING..........................................................................43

CONSERVATION FOR WINTER OPERATION ....................43

STORAGE ...........................................................................43

Re-initation after time of storage....................................43

TECHNICAL SPECIFICATIONS - CHASSIS...........................44

TECHNICAL SPECIFICATIONS - ENGINE ..........................46

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

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

INDEX

ENGLISH

5

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 fitted on the left hand side of the handle bar. When
engine is cold, there should allways be a play of 1–3 mm (0,04–0,1 in) at
this lever (measured at outer edge).

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 is mounted on the handlebar on the right and
actuates the front wheel brake.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

1-3 mm

1

2

ENGLISH

6

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 CLOCK 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.

1

2

3

TEST

WS

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

ENGLISH

7

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

1

1

2

2

2

ENGLISH

8

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. 50°C. Each additional bar
represents 10°C more. When the upper bar lights up, all of the bars will
start to blink and the red warning lamp

2 will light up.



WARNING



P

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

FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP

(ALSO SEE PAGE 33):
– DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES
– NOT ENOUGH COOLING LIQUID IN THE SYSTEM
– THE VENTILATOR ON THE LEFT 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 light will light up when the cooling liquid has
reached a temperature of approx. 110°C.

The orange warning light will start to blink when the fuel level has
reached the reserve mark. At the same time the display will auto­matically change to TRIP F (see TRIP 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 .

110°C (230°F)

100°C (212°F)

90°C (194°F)

80°C (176°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

1

2

3

4

ENGLISH

9

Combination switch

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

= High-beam light

= Low-beam light

The indicator switch

2 returns to central position after actuation.

Press flasher switch towards switch housing to switch off the flasher.

The horn is sounded with button

3.

The light signal (high beam) is actuated with button

4.

Starter tip switch, emergency OFF tip switch, light switch

Use the starter tip switch 5 to operate the electric starter.

The light switch has 3 positions:

= Light off

= Parking light on

= Headlight on

The emergency off switch

6 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).

Filler cap

The filler cap 7can 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.

4

1

1

2

3

5

6

7

ENGLISH

10

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

1

N

OFF ON RES

S

E

R

F

U

E

F

L

F

O

N

O

S

E

R

F

U

E

F

L

F

O

N

O

S

E

R

F

U

E

F

L

F

O

N

O

ENGLISH

11

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 0518X730 .............20 Klicks (640 LC4)

WP 1418X738 .............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 0518X730 .............12 Klicks (640 LC4)

WP 1418X738 .............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 0118X729 .............Position 3 (640 LC4)

WP 0118X730 .............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 0118X729 .............Position 7 (640 LC4)

WP 0118X730 .............Position 8 (640 LC4 Supermoto)



WARNING



–N

EVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS.

–THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED

NITROGEN

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

MAINTENANCE WORK YOURSELF

. SEVERE INJURIES COULD BE THE RESULT.

Holding bars

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

1

3

4

A

2

2

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12

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



–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER

KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A

JACKET

, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A

SHORT TRIP

. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY

COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS
POSSIBLE

. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE

CLOTHING

.

–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

.

–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

.

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

ENGLISH

13

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.

DRIVING INSTRUCTIONS

ENGLISH

14

Starting when the engine is cold

1 Open the fuel tap

1

2 Switch on ignition (turn ignition key 2into position ).
3 Switch on emergency OFF switch

3

.

4 Switch transmission to idle (green indicator lamp N

4

lights up).

5 Operate cold starting device (choke)

5

.

6 Do not accelerate; operate starter button

6

.

7 If the engine starts, push the choke lever back a little bit, as soon as the

engine runs unevenly.

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



WARNING



–

T

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

KICKSTARTER

.

–DONOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH

.

A

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 2into position ).
3 Switch on emergency OFF switch

3

.

4 Switch transmission to idle (green indicator lamp N

4

lights up).

5 Do not accelerate; operate starter button

6

.

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

What to do when the engine is „flooded”

The throttle must be fully opened when starting. If necessary change spark­plug.

1

2

4

6

3

5

ENGLISH

15

Kickstart instructions

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

.

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



B

EFORE YOU START OFF, CHECK THAT THE MAIN STAND HAS BEEN SWUNG

UP FULLY

. IFTHE 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 the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to
NEUTRAL.



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

.

–AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

!

CAUTION

!

–H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. WERECOMMEND 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

105°C.

POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE:

-LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR

TEMPERATURES

-LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT

-FAN AT LEFT RADIATOR IS NOT RUNNING

-IMPROPER 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

.

–I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

.

–I

NTHE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION

-RELATED NOISE, STOP IMMEDIATELY,

TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER.

Braking

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



WARNING



– IN THE RAIN, OR AFTER THE MOTORCYCLE HAS BEEN WASHED,

BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS. FIRST,
THE BRAKES MUST BE BRAKED DRY.

– ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED

AS WELL

. FIRST, THE BRAKES MUST BE BRAKED CLEAN.

–W

HEN 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

.