KTM Motorcycle 640LC4 User Manual

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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 sports motorcycle that guarantees to

bring you lots of fun and enjoyment, provided that you clean and maintain it

appropriately. Before you go for your first ride, be sure to read this manual

carefully and thoroughly in order to familiarize yourself with how to operate

your new motorcycle and with its characteristics, even if this means that you

have to dedicate some of your valuable time to this task. Only by doing so will

you learn how to tune your motorbike to your specific needs and how to protect

yourself against injury. Besides, this manual contains important information on

motorcycle maintenance. At the time this manual was typeset, it was up-to-date

with the latest state of this production series. It cannot be completely ruled out,

however, that there may exist minor discrepancies resulting from further design

upgrades of these motorcycles.

This manual is an important part of your motorbike and should be passed on to

any subsequent owner in case you decide to sell it.

Many motorcyclists have a good working knowledge of motorcycle mechanics; if

this is true in your case, you will be able to use this manual to carry out most of

the maintenance steps yourself. If, on the other hand, you are not very familiar

with motorcycles, it might be better to have a professional KTM dealer perform

those steps marked described in the chapter entitled “Maintenance Work on

Chassis and Engine” of this manual.

For your own safety use only KTM-approved parts and accessories. KTM is not

liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance

intervals. Heeding these guidelines will significantly increase the life of your

motorcycle. Have services carried out by a KTM dealer so that your warranty

claim remains intact.

Contact a specialized KTM workshop supported by the KTM importer if you have

any special wishes. Please remember to wear a helmet, protective glasses and

protective clothing while driving. KTM drivers are considerate drivers.

We wish you a lot of fun when driving !

KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the

beginning of an on-going total re-engineering quality plan for a brighter tomorrow.

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

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INDEX

Page

SERIAL NUMBER LOCATIONS .............................................4

Page

Check the rear brake fluid level ......................................21

Refilling the rear brake fluid reservoir .............................21

Checking the rear brake pads .........................................21

Dismounting and mounting the front wheel (LC4) .........22

Dismounting and mounting the front wheel (LC4 Supermoto).22

Chassis number ................................................................4

Engine number, engine type.............................................4

OPERATION INSTRUMENTS ...............................................4

Clutch lever......................................................................4

Hand decompression lever................................................4

Choke lever......................................................................5

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

Speedometer, indicator lamps...........................................5

Ignition lock .....................................................................5

Combination switch..........................................................6

Starter tip switch, emergency OFF switch.........................6

Filler cap...........................................................................6

Fuel..................................................................................6

Fuel tap............................................................................7

Shift lever.........................................................................7

Kickstarter ........................................................................7

Foot brake pedal ..............................................................7

Compression damping of fork ..........................................8

Rebound damping of fork ................................................8

Compression damping of shock absorber .........................8

Rebound damping of shock absorber ...............................8

Holding bars.....................................................................8

DRIVING INSTRUCTIONS ....................................................9

Dismounting and mounting the rear wheel.....................23

Checking the shock absorbtion rubbers in the rear hub.......23

Tires, air pressure............................................................24

Checking spoke tension..................................................24

Battery ...........................................................................25

Charging the battery ......................................................25

Main fuse.......................................................................26

Fuses for individual power-consuming units ...................26

Exchanging the headlight lamp.......................................26

Replacing the parking light bulb .....................................26

Exchanging the brake light and tail light bulb .................27

Cooling system...............................................................27

Checking the cooling liquid level ....................................28

Cleaning the air filter......................................................28

Adjusting idling speed ....................................................28

Adjusting the throttle cable ............................................29

Draining the carburetor float chamber............................29

Adjusting the clutch cable...............................................29

Checking and adjusting the chocke cable play................30

Checking the adjustment of the hand decompression cable .....30

Engine oil .......................................................................30

Checking the engine oil level..........................................30

Oil circuit........................................................................31

Oil and fine screen filter change, bleeding of the oil system 31

Changing oil filter ..........................................................32

TROUBLE SHOOTING........................................................33

CLEANING..........................................................................36

PERIODIC MAINTENANCE-SCHEDULE..............................14

MAINTENANCE WORK ON CHASSIS AND ENGINE ..........16

Tool set ..........................................................................16

Removing the seat..........................................................16

Checking and adjusting steering head bearing................17

Changing the spring preload of the shock absorber........17

Lubricate shock absorber linkage....................................17

Checking rubber ring on the rear shock absorber............18

Checking chain tension...................................................18

Correct chain tension......................................................18

Chain maintenance.........................................................18

Chain wear.....................................................................19

General information on KTM disc brakes........................19

CONSERVATION FOR WINTER OPERATION ....................36

STORAGE...........................................................................36

Re-initation after time of storage....................................36

TECHNICAL SPECIFICATIONS - CHASSIS...........................37

ECHNICAL SPECIFICATIONS - ENGINE ..........................38

Adjisting of free travel at the hand brake lever ...............19

Checking of brake fluid level - front brake......................20

CONSUMER INFORMATION FOR USA ONLY ..................40

HEAD WORD INDEX..........................................................43

Refilling the front brake fluid reservoir............................20

Checking the front brake pads........................................20

Changing the basic position of the foot brake pedal.......20

APPENDIX

WIRING DIAGRAM................................................

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SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is stamped on the right side of the steering head tube.

Write this number into the relevant area on page 1.

Engine number, engine type

The engine number and engine type are stamped on the right hand side of

the engine below the chain sprocket. Write this number into the relevant

area on page 1.

OPERATION INSTRUMENTS

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).

1-3 mm

CAUTION

IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE

CLUTCH WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS.

Hand decompression lever

The hand decompression lever 2is 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.

CAUTION

THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED

(SEE MAINTENANCE WORK). A LACK OF PLAY IN THE HAND DECOMPRESSION LEVER CAN

RESULT IN ENGINE DAMAGE.

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Choke lever

If the choke lever 1 is pulled backwards, a bore will be opened in the

carburetor through which the engine may draw in additional fuel. This

produces a „rich“ fuel/air mixture necessary for cold start. If the choke lever

is pushed forward up to the stop, the bore will be closed again. In this

position the choke cable must have a play of approx. 4 mm.

CAUTION

IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER SYSTEM

CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN

UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON AND CYLINDER.

Hand brake lever

The hand brake lever is mounted on the handlebar on the right and

actuates the front wheel brake.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”

(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE

BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE

BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

Speedometer, indicator lamps

The mileage indicator Ain the speedometer 2indicates overall mileage. The

day mileage indicator B can be set to 0 by means of the setting wheel C.

Turn the setting wheel forward until only zeros can be seen in the display.

The green indicator lamp flashes when the flasher light is working in

the same rhythm as the flasher light.

The green indicator lamp lights up when the gear is switched to idle.

The blue indicator lamp lights up when the high beam is on.

The red cooling liquid temperature warning lamp lights up at a

cooling liquid temperature of 105°C (223°F).

CAUTION

POSSIBLE CAUSES FOR THE RISE IN TEMPERATURE AND THE LIGHTING OF THE RED

COOLING LIQUID TEMPEREATURE WARNING LIGHT:

– SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE

– TOO LITTLE COOLING LIQUID IN THE SYSTEM

– THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING

– EXCESSIVE USE OF THE CLUTCH AT SLOW SPEED

(SEE PAGE 27 )

Ignition lock with 4 switch positions

Switch positions of ignition lock 3:

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

Ignition on, light off (engine can be started)

Ignition on, light on (engine can be started) Riding just with lights!

Ignition off, light 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

Ignition lock with 3 switch positions

Switch positions of ignition lock 4:

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

Ignition on, light on (engine can be started)

Ignition off, light off, handlebar blocked

To switch the ignition to position

turn the ignition key to position

and firmly press it into the lock. Turn the handlebar all the way to

the left, then turn the ignition key to the left.

The ignition key can be withdrawn in position

and

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Combination switch

The rocker switch LIGHTS 1actuates 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

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

CAUTION

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

5 SECONDS BEFORE TRYING AGAIN.

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

circuit are switched on).

The engine cannot be started in position

circuit are interrupted).

(ignition circuit and starter

Filler cap

The filler cap

can be locked and is provided with a fuel evaporation

control system.

To open the cap insert the ignition key, turn it 90° counterclockwise, then

lift off the filler cap.

To close the tank insert the filler cap, turn the ignition key 90° clockwise

and take out the key.

Fuel

The LC4 engine needs premium gasoline with an octane number of 95

or higher.

CAUTION

USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY

GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED

WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN

FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING.

BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE

ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN

THE EYES, SEEK A DOCTOR’S ADVICE IMMEDIATELY.

35 mm

Fuel expands when its temperature rises. Therefore do not fill the tank to

the top (see fig.).

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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.

CAUTION

THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP

IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE

ENGINE.

OFF

RES

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.

2,3,4,5

Kickstarter

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

be swivelled.

WARNING

– WHEN STARTING THE ENGINE, MAKE SURE THAT YOU ALWAYS WEAR STURDY

MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY. YOU MIGHT SLIDE OFF THE

KICKSTARTER, OR THE ENGINE MAY CAUSE THE KICKSTARTER TO RECOIL, THEREBY

CAUSING INJURIES TO FOOT AND LEG.

–

ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND, WHILE DOING SO, NEVER

OPEN THE THROTTLE. KICKSTARTING WITH INSUFFICIENT MOMENTUM AND AN

OPENED THROTTLE LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL.

Foot brake pedal

The foot brake pedal is located in front of the right footrest. Its basic

position can be adjusted to your seat position (see maintenance work).

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”

(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE

BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING

THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

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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 0518W714.......20 Klicks

WP 0518W722.......14 Klicks

(640 LC4)

(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 counter-

clockwise 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 0518W714.......12 Klicks

WP 0518W722.......14 Klicks

(640 LC4)

(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 0118W724............Position 6

WP 0118W721............Position 5

(640 LC4)

(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 0118W724............Position 7

WP 0118W721............Position 7

(640 LC4)

(640 LC4 Supermoto)

WARNING

– NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS.

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

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

MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

Holding bars

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

vehicle.

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DRIVING INSTRUCTIONS

– Adjust the hand brake lever and the foot brake pedal to the

Check the following before each start

most comfortable positions for you.

When you start off, the motorcycle must be in a perfect tech-

nical condition. For safety reasons, you should make a habit of

performing an overall check of your motorcycle before each

start.

– Get used to handling the motorcycle on an empty car park,

before starting on a longer drive. Also try to drive as slowly

as possible and in standing position, to improve your feeling

for the vehicle.

– Do not drive along off-road tracks which go beyond your

ability and experience.

The following checks should be performed:

1 CHECK THE 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.

3 CHAIN

– Hold the handlebar with both hands and leave your feet on

the foot rests while driving.

–

Remove your foot from the foot brake pedal when you are

not braking. If the foot brake pedal is not released the brake

pads rub continuously and the braking system is

overheated.

A loose chain can fall off; an extremely worn chain can tear,

and insufficient lubrication can result in unnecessary wear to

the chain and rear sprockets.

– You may only be accompanied by a passenger if your

motorcycle is fitted and registered for such purposes. The

passenger must hold tight to the brackets or hold on to the

driver during the drive, with his feet on the passenger foot

rests.

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 reduce the driving performance.

5 BRAKES

– 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

Check the brakes for proper functioning as well as the

brake-fluid level in the tanks. The reservoirs have been

designed in such a way that brake fluid does not need to be

refilled even when the brake pads are worn. If the level of

brake fluid falls below the minimum value, this indicates a

leak in the braking system or completely worn out brake

pads. Arrange for the braking system to be checked by a

KTM specialist garage, as complete failure of the

braking system can be expected.

– Luggage

–

Driver and passenger with protective clothing and helmet.

Also check the state of the brake hoses and the thickness of

the brake linings.

– Pay attention to running in instructions.

Check free travel at hand brake lever and foot brake pedal.

6 CABLES

Check correct setting and easy running of all control cables.

7 COOLING LIQUID

Check the level of cooling liquid when the engine is cold.

8 ELECTRICAL SYSTEM

Check headlight, parking light, tail light, brake light,

flashers, indicator lamps and horn for faultless operation.

9 LUGGAGE

Running in the LC4 models

Even finely machined surfaces of engine parts have rougher

surfaces than parts that slide on each other for a long time.

Therefore, every engine must be run in. For this reason, do not

demand maximum performance from the engine for the first

100 kilometers. The vehicle must be run in at low, changing

performance level for the first 1000 KM (620 miles). The

engine speed of 4800 r.p.m. must not be exceeded during the

first 1000 kilometers (620 miles). During this break-in time,

you should ride your motorcycle in different conditions. The

following table shows you the maximum velocity values in the

different gears at 4800 r.p.m. as based on the rear wheel

transmission ratio of your motorcycle.

If you are taking luggage with you, check that this is

securely fastened.

WARNING

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER

KTM DRIVERS ALWAYS WEAR HELMET, BOOTS, GLOVES AND

JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A

SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY

COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS

EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED

SUITABLE PROTECTIVE CLOTHING.

Exceeding the above listed rotations as well as pushing high

rpm when the engine is cold will have an adverse effect on the

life of your engine.

640 LC4 Supermoto

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

ratio

gear

16:42 t 17:42 t

– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

– ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR

EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF

THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT

DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING

PROPERTIES.

1st

35 (22) 35 (22)

50 (32) 50 (32)

70 (44) 70 (44)

90 (57) 90 (57)

100 (63) 100 (63)

km/h (mph)

2nd

3rd

4th

5th

– THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH

TIRES THAT HAVE THE SAME PROFILE TYPE.

NOTE:

DURING THE STAGE OF RUNNING THE ENGINE IN, THAT IS THE FIRST

1000 KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF

MINERAL OIL FORMULA. THIS ALSO APPLIES IF THE ENGINE HAS BEEN

REPAIRED.

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read the entire manual carefully before your first drive.

– Familiarize yourself with the operating elements.

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Starting when the engine is cold

1 Open the fuel tap

2 Switch on ignition (turn ignition key

into position ).

3 Switch on emergency OFF switch

4 Switch transmission to idle (green indicator lamp N

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

–

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

^KICKSTARTER.

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

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.

ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

CAUTION

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

5 SECONDS BEFORE TRYING AGAIN.

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

COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED

CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP

BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM.

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE

STARTER TIP SWITCH:

– the transmission is switched to idle

– Check if the emergency OFF switch is on

– Check if the ignition is on

– the headlight is on (ignition lock in position ).

– If this is not the case, the battery is discharged

– If the lights 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:

This motorcycle is equipped with a safety starter system. The engine can

only be started when the transmission is switched to idle or the clutch lever

is pulled, respectively.

NOTE LC4 SUPERMOTO:

This motorcycle is equipped with a safety starter system. The engine can

only be started when the transmission is switched to idle or the clutch lever

is pulled, respectively.

Motorcycles with side stands are also equipped with a safety starting

system.

If you put in a gear with the side stand in its swung-out position, and if you

let go of the clutch lever, the engine will stop.

Starting when the engine is warm or hot

1 Open the fuel tap

2 Switch on ignition (turn ignition key

into position ).

3 Switch on emergency OFF switch

4 Switch transmission to idle (green indicator lamp N

lights up).

5 Do not accelerate; operate starter button

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

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– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.

– A DEFORMED HANDLEBAR MUST ALWAYS BE REPLACED. UNDER NO

CIRCUMSTANCES SHOULD YOU STRAIGHTEN THE HANDLEBAR WHICH

WOULD CONSEQUENTLY LOSE ITS STABILITY.

What to do when the engine is „flooded”

The throttle must be fully opened when starting. If necessary

change spark-plug.

Kickstart instructions

CAUTION

Start as described above, then push the kickstarter hard ALL

THE WAY.

– 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.

WARNING

– WHEN STARTING THE ENGINE, MAKE SURE THAT YOU ALWAYS WEAR

STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY. YOU

MIGHT SLIDE OFF THE KICKSTARTER, OR THE ENGINE MAY CAUSE THE

KICKSTARTER TO RECOIL, THEREBY CAUSING INJURIES TO FOOT AND LEG.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

–

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.

LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE

VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE

MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

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

LEAD TO ENGINE DAMAGE.

– NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER. OTHERWISE

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

Starting off

–

THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT

Pull the clutch lever. Put the engine into first gear, slowly

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

TEMPERATURE HAS REACHED 105°C.

POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE:

-LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR

TEMPERATURES

WARNING

– BEFORE YOU START OFF, CHECK THAT THE MAIN STAND HAS BEEN

SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE

MOTORCYCLE CAN GO OUT OF CONTROL.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

-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.

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.

– IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT.

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

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY,

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

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.

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.

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.

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

– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING

TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE

RECOGNIZED AS EARLY AS POSSIBLE.

– ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS

– AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND

ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE

CONTROL OVER YOUR MOTORCYCLE.

–

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

BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS. FIRST,

THE BRAKES MUST BE BRAKED DRY.

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

AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN.

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER

AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE

WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING

SYSTEM CAN FAIL.

–

WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION

LOCK TO POSITIONS AND

RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR

GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY

SITUATION.

–

– WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE.

– REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY

OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

GOGGLES, YOU WILL BE PRACTICALLY BLIND.

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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.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS

RUNNING.

– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE

ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK

ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER

OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE

NOT LIKELY TO TOUCH IT AND GET BURNED

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE

TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

CAUTION

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CARBURETOR

CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE.

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT

IT CANNOT BE USED BY UNAUTHORIZED PERSONS.

NOTE REGARDING THE CENTER STAND:

We advise the following procedure to place the motorcycle on the center

stand as effortlessly as possible:

a) press main stand to ground using foot

b) swing out kickstarter and pull motorcycle backwards at an angle as

illustrated (see illustration).

Make sure that the ground is solid and that your motorcycle is standing

securely.

CAUTION

THE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY. BY

SITTING ON THE MOTORCYCLE, YOU WILL PUT ADDITIONAL WEIGHT ON THE CENTER

STAND, POSSIBLY CAUSING THE CENTER STAND OR FRAME TO BE DAMAGED OR THE

MOTORCYCLE TO FALL DOWN.

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.

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640 LC4

640 LC4 SUPERMOTO

PERIODIC MAINTENANCE SCHEDULE

2. Service after

5000 km, then

every 5000 km or

once a year

1. Service

after

1000 km

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

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

every 2 years

or 20000 km

at least

once a year

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

●

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

SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM.

MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!

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

before each

start

after every

cleaning

for cross

country use

once a year

Check oil level

●

Check brake fluid level

Check brake pads for wear

Check lighting system for proper operation

Check horn for proper operation

Lubricate and adjust actuating cables and nipples

Bleed fork legs in regular intervals

Remove and clean fork dust sleeves in regular intervals

Clean and lubricate chain as necessary

Check chain tension

●

Clean air filter and filter box

Check tire pressure and wear

●

Check coolant level

Check fuel lines for leaks

Drain float chamber

●

Check all control elements for smooth running.

Check brake performance

●

Treat exposed metal components (except for the braking and exhaust

systems) with wax-based anti-corrosion agents

Treat ignition/steering lock and light switch with contact spray

Check all screws, nuts, and hose clamps for their tight fit

●

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MAINTENANCE WORK ON CHASSIS AND ENGINE

WARNING

ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGE

AND SKILLS OF A PROFESSIONAL. IN THE INTEREST OF YOUR OWN SAFETY, HAVE THESE PROCEDURES CARRIED

OUT AT A KTM SERVICE STATION! AT KTM YOUR MOTORCYCLE WILL RECEIVE OPTIMAL SERVICING BY

SPECIALLY TRAINED MECHANICS.

CAUTION

– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS,

CARBURETOR, ELECTRIC CONNECTORS ETC.

– WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IF THE

MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK

– DO NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP

WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS.

– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

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

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

1,000.000 LITERS WATER.

–

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

IF YOU UNFASTEN SCREWS AND NUTS SECURED BY LOCTITE, YOU HAVE TO REATTACH AND SECURE THEM IN THE SAME WAY. SEE TECHNICAL SPECIFI-

CATIONS - FASTENING TORQUES ON PAGE 39.

Tool set

The tool set 1is 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 3.

To mount the seat hook it into the oval head screw, lower the rear part of

the seat and push the whole seat forwards. If necessary push the middle of

the seat slightly down to let the retaining bracket

engage with the seat.

Finally fasten the seat with the corresponding screw.

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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

15 Nm (11 ft.lb).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTOR-

CYCLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF

CONTROL.

CAUTION

IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, FIRST

THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.

At least once a year, the steering head bearings should be greased.

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 4 changes the spring preload by

approximately 1,75 mm (0,07 in).

Loosen the locking ring 3with the hook wrench from the tool set. Change

the spring preload with the adjusting ring 4and retighten the locking ring.

BASIC SETTING – SPRING PRELOAD

WP 0118W724............A = 23,5mm (640 LC4)

WP 0118W721............A = 15mm (640 LC4 Supermoto)

Lubricating the shock absorber linkage

The bearings in the rocker arm must be greased (Shell Advance Grease) in

regular intervals. For this purpose, a grease nipple 5 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.

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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.

min. 2,5 mm

CAUTION

NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK

ABSORBER.

WARNING

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

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

MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

Checking chain tension

Support the motorcycle on the center stand or side stand, respectively.

Switch transmission to neutral.

Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain

sliding component until the upper part of the chain is tensioned (see

illustration)

Now, the distance A between chain and swingarm should be 0 mm. The

upper part of the chain Bmust be tight (see illustration).

Correct chain tension, if necessary!

WARNING

– IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER TRANS-

MISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL BEARINGS)

WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND

EVEN CHAIN BREAKAGE.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

16:42

17:42

A = 0 mm

Correct chain tension

Loosen collar nut

adjusting screws

, loosen counter nuts

, and turn right and left

equally far. Tighten counter nuts

Before tightening the wheel spindle, verify that the chain adjusters

are

sitting close to the adjusting screws and that the rear wheel has been

aligned with the front wheel.

Tighten collar nut

with 80 Nm (60 ft.lb).

WARNING

IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE

THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A

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

Chain maintenance

For long chain life, good maintenance is very important. X-ring chains

require only modest maintenance. The best way is to use lots of water, but

never use brushes or solvents. After letting the chain dry, you can use a

special X-ring chain spray (Shell Advance Bio Chain).

WARNING

NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK, EITHERWISE

THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY

REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL.

CAUTION

WHEN MOUNTING THE CHAIN JOINT, THE CLOSED SIDE OF THE SAFETY DEVICE MUST

POINT IN RUNNING DIRECTION.

✓

Also check sprockets and chain guides for wear, and replace if necessary.

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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 (10,70 in) is measured. Chains do not

always wear off evenly, therefore repeat the measurement at different

places on the chain.

15 KG

NOTE: If you mount a new chain, the sprockets should also be replaced.

New chains wear faster if used on old used sprockets.

General informations about KTM disc brakes

BRAKE CALIPERS:

The brake calipers of this series “float“. This means that the brake calipers

are not solidly attached to the caliper support. Thus, the brake pads are

always in optimum contact with the brake disc. Secure the screws of the

caliper support with Loctite 243 and tighten to 25 Nm (19 ft.lb).

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.

max. 272 mm

WARNING

16 17 18

BRAKE SHOES AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZED FOR

OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE SHOE'S DESIGN

AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN DEVIATE SIGNIFI-

CANTLY FROM ORIGINAL KTM BRAKE SHOES. IF YOU USE DIFFERENT BRAKE SHOES THAN

THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT CANNOT BE WARRANTED THAT

THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC. YOUR MOTORCYCLE WILL NOT LON-

GER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD

TRAFFIC AND THE WARRANTY WILL BE VOID.

BRAKE FLUID RESERVOIRS:

DOT

5.1

DOT

The brake fluid reservoirs on the front and rear wheel brakes have been designed in

such

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 FLUID:

✓

KTM fills the brake systems with Shell Advance Brake DOT 5.1 brake fluid,

one of the best brake fluids that is currently available. We recommend that

you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of

an amber color. If you do not have any DOT 5.1 for refilling, you may use

DOT 4 brake fluid. However, you should replace it as soon as possible

by DOT 5.1.

Never use DOT 5 braking fluid. It is based on silicone oil and has a purple

color. Gaskets and brake hoses are not compatible with it.

BRAKE DISCS:

Wear reduces the thickness of the brake disc in the area of contact 1with

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

– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM CONSTITUTE A SAFETY

HAZARD. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON AS IT REACHES ITS

WEAR LIMIT.

– AS A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT

BY A LICENSED KTM MECHANIC.

Adjusting of free travel at the hand brake lever

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

screw 2. In this way, the position of the point of pressure (i.e., the

resistance you feel on the hand brake lever when the brake pads are

pressed against the brake disc) can be adjusted for any hand size.

CAUTION

min. 3 mm

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM. ONLY THEN MAY

THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY THE

GREATER RESISTANCE OF THE HAND BRAKE LEVER). 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.

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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

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

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN

AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir*

Loosen screws 1and remove lid 2and membrane 3.

If necessary, dismount the mirror and loosen the throttle grip.

Place hand brake cylinder in a horizontal position and fill the brake fluid

reservoir to 5 mm (0,2 in) below the rim with brake fluid DOT 5.1 (Shell

Advance Brake DOT 5.1). Replace membrane and lid, tighten screws. Rinse

off spilled or overflowing brake fluid with water.

WARNING

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

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

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR.

– THE BRAKE FLUID RESERVOIRS ON THE FRONT AND REAR WHEEL BRAKES HAVE BEEN

DESIGNED IN SUCH A WAY THAT EVEN IF THE BRAKE PADS ARE WORN IT IS NOT

NECESSARY TO TOP UP THE BRAKE FLUID. IF THE BRAKE FLUID LEVEL DROPS BELOW

THE MINIMUM EITHER THE BRAKE SYSTEM HAS

LEAK OR THE BRAKE PADS ARE

COMPLETELY WORN DOWN.

IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

5 mm

CAUTION

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

REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the front brake pads

The brake pads can be inspected from below. The linings must be at least

1 mm (0,04 in) thick.

min.

1 mm

WARNING

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

1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY

DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE

DISC, IMPAIRING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Changing the basic position of the foot brake pedal*

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

roller . The free play at the foot brake pedal must then be adjusted by

means of the piston rod

Measured on the outside, the foot brake pedal must have 3-5 mm

(0,12–0,20 in) of free play, before the piston rod can move the piston in the

brake cylinder (to be recognised from the resistance on the foot

brake pedal).

CAUTION

IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM

WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE PADS.THE BRAKING SYSTEM

OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES.

3-5mm

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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

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

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN

AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir*

When the brake fluid level has dropped to the MIN mark, you need to refill

the brake fluid reservoir.

For easier access to the brake fluid reservoir it is recommended to remove

the hexagon screw . Then move the container outwards as indicated in

the illustration. Remove plug

with rubber boot

and add brake fluid

DOT 5.1 (Shell Advance Brake 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

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

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

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR

– THE BRAKE FLUID RESERVOIRS ON THE FRONT AND REAR WHEEL BRAKES HAVE BEEN

DESIGNED IN SUCH A WAY THAT EVEN IF THE BRAKE PADS ARE WORN IT IS NOT

NECESSARY TO TOP UP THE BRAKE FLUID. IF THE BRAKE FLUID LEVEL DROPS BELOW

THE MINIMUM EITHER THE BRAKE SYSTEM HAS

LEAK OR THE BRAKE PADS ARE

COMPLETELY WORN DOWN.

IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

CAUTION

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

REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings

may not be less than 1 mm (0.04 in).

min.

1 mm

WARNING

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

1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY

DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE

DISC, IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

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

Hold the front wheel and withdraw the wheel spindle 3.

Note: The wheel spindle can be withdrawn more easily by turning it mode-

rately with a 6 mm ALLAN/IMBUS key while pulling.

Remove front wheel carefully from the fork and take the speedometer drive

4off the hub.

CAUTION

–

DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED.

– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING

UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

Prior to mounting the front wheel, clean and grease sealing ring 5 and

running surface 6at the speedometer drive.

To mount the front wheel, lift it into the fork. Insert speedometer drive into

the hub. Make sure that the driving tabs 7 engage with the slots of the

drive.

Position front wheel and speedometer drive, and mount wheel spindle.

The speedometer shaft must be placed as running along the outsideof the

fork guard and pass the triple clamp in front between fender and fork leg.

Screw on the collar nuts 1 without tightening them. Make sure that the

speedometer drive runs upwards and parallel to the fork leg (see below).

Tighten the clamp screws 2on the right fork leg so as to prevent the wheel

spindle from twisting, and then tighten the collar nuts with 40 Nm.

Loosen the clamp screws on the right fork leg. Take the motorcycle down

from its stand. Press the front wheel brakes and push down 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(7 ft. lbs).

WARNING

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS

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

MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

Dismounting and mounting the front wheel (LC4 Supermoto)

The front wheel of the Supermoto is essentially removed in the same

manner as the front wheel of the LC4-E. However, the brake caliper has

first to be removed. To remove the front brake caliper, remove both screws

8and 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 8 and apply Loctite

243. Tighten the screws with 25 Nm(19 ft. lbs).

WARNING

THE SCREWS 8MUST BE SECURED WITH LOCTITE 243.

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Dismounting and mounting the rear wheel (LC4)

Park the motorcycle on the center stand. The rear wheel must not touch the

ground.

Loosen the collar nut 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

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING

UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

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

COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE (SHELL ADVANCE

GREASE) TO PREVENT THE THREAD FROM JAMMING.

NOTE: If the rear wheel has been dismounted, you should also check the

shock absorption rubber.

The rear wheel is remounted in reverse order. Before tightening the collar

nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain

tensioners lie on the tension screws.

Dismounting and mounting the rear wheel (LC4 SUPERMOTO)*

To remove the front wheel, jack the motorcycle up on its frame so that the

front wheel no longer touches the ground.

Remove rear screw 4from the chain guard.

To avoid damage to the rim and to fix the brake caliper, stretch a rubber

band or an old hose between the brake caliper and the side stand (see

illustration).

Remove collar nut 1, remove chain tensioner 2, hold on to the rear wheel

while you pull out wheel spindle 3.

Push the rear wheel as far forward as possible and remove the chain from

the sprocket. Carefully push the rear wheel back, lift slightly and swivel to

the left. Carefully lift the wheel diagonally towards the rear and remove

from the swing arm. Do not use force to remove the rear wheel to avoid

damaging the rim.

NOTE: If the rear wheel has been dismounted, you should also check the

shock absorption rubber.

The rear wheel is remounted in reverse order. Before tightening the collar

nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain

tensioners lie on the tension screws.

WARNING

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS

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

OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE

PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE, OTHER-

WISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

Checking the shock absorption rubbers in the rear hub *

LC4 models have a damped rear wheel hub. For this purpose, the engine

power is conveyed from the rear sprocket via 6 shock absorption rubbers 5

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

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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

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

APPROVED TIRES MAY BE USED. OTHER TIRES CAN HAVE A NEGATIVE EFFECT ON RIDING

PERFORMANCE (E.G. VIBRATION AT HIGHER SPEEDS).

Approved tires for 640 LC4 (as of September 2001)

METZELER . . . . . . . . . . . . . .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.

TIRES - AIR PRESSURE

front

rear

640 LC4

– Refer to the specific regulations in your country for minimum tire tread

requirements. We recommend replacing tires at the latest when the

tread is down to 2 mm.

– Tire pressure should be checked regularly on a “cold” tire. Proper pres-

sure ensures optimum driving comfort and extends the life of your tires.

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

WARNING

– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES

COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES.

– USE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS.

– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.

Road, driver only

2,0 bar (29psi) 2,2 bar (31psi)

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

– WORN TIRES CAN HAVE

NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

PERFORMS, ESPECIALLY ON WET SURFACES

– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE TIRE

CAN RESULT

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels

and thus for riding safety. A loose spoke causes the wheel to become un-

balanced and before long other spokes will have come loose. Check spoke

tension, especially on a new 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

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

AN UNSTABLE HANDLING OF YOUR MOTORCYCLE.

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

SPOKES MUST BE TENSIONED TO 4 NM.

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Battery

The battery is mounted under the seat (remove the seat, see page 16).

The battery has a closed system and therefore requires no maintenance. It is

not necessary to check the electrolyte level or to refill water. Simply keep

the battery poles clean and slightly grease them with an acid-free grease if

necessary.

Removing the battery:

First disconnect the negative and then the positive pole of the battery.

Remove screws

the way.

and swing retaining bracket and voltage regulator out of

Remove battery.

When replacing, connect first the positive and then the negative pole.

WARNING

– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH GREAT

CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.

– IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER.

– IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH WATER

FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR!

– THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES.

AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY.

– DEFECT BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN. ENSURE

PROPER DISPOSAL OF DISCARDED BATTERIES.

CAUTION

– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR 2!

– NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL

DESTROY THE RECTIFIER-REGULATOR.

BATTERY STORAGE:

When preparing the motorcycle for a longer period of standstill, remove the

battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not

expose to direct sun radiation.

Charging the battery

Remove the battery and check the charging level. Use a voltmeter to

measure the voltage between the battery poles (off-load voltage).

off load voltage

Volt

charging level

charging time

0,8 A

charging voltage

VOLT

>12,7

~12,5

~12,2

~12,0

~11,8

100

––

4 h

max.

7 h

14,4 V

11 h

14 h

Accurate results can only be obtained if the battery has neither been char-

ged nor discharged during a period of 30 minutes preceding the measuring.

If the battery is empty, it can be recharged for a maximum period of

10 hours at 0.8 A and a maximum of 14.4 V.

CAUTION

– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR

– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE

CHARGING UNIT ON.

– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTI-

LATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS.

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

OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES.

– AVOID QUICK CHARGING IF POSSIBLE.

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Main fuse

Located near the battery under the seat, the main fuse 1protects all power

consumers.

Replace a blown fuse only with an equivalent one. If a new fuse that has

just been set in gets blown again, you are strongly advised to have it

inspected by a KTM dealer.

The fuse capacity is 20 Ampere.

CAUTION

UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE

ALLOWED TO BE “REPAIRED”. AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE

ELECTRICAL INSTALLATION!

Fuses for individual power-consuming units

Additional fuses separately protecting different power-consuming units are

mounted under the headlight mask.

For instructions to remove and mount the headlight mask please refer to

"Exchanging the headlight lamp".

Fuse

(10 Ampere) protects the following power-consuming units:

– headlight

– parking light

Fuse

(10 Ampere) protects the following power-consuming units:

– flasher lights

– brake light

– horn

– radiator fan motor

Fuse

(10 Ampere) protects the following power-consuming units:

– ignition

– starter system

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

Remove the headlight mask:

Remove screws

on the left and on the right side.

Depress the front section of the fender, pull the headlight mask upwards,

unhook it from the lower part of the fender, then swing it forwards.

Exchanging the headlight lamp:

Disconnect plug

from the bulb.

Remove the rubber cap

Unhook the retaining bracket, then remove the bulb.

When inserting the new bulb make sure that the wider of the 3 tongues

is located in the corresponding groove in the socket.

CAUTION

NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF THE BULB

MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHERWISE CAUSE THE

GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR.

Hook in the retaining bracket, mount the rubber cap and connect the plug

to the bulb.

Mounting the headlight mask:

Appropriately position the headlight mask. The headlight must be

located below the cockpit.

Depress the front part of the fender, pull the headlight mask upwards and

insert the retaining pins

into the corresponding bores of the fender.

Mount the screws

Replacing the parking-light bulb

Disassemble the headlight as described above and simply pull the bulb

socket bkout of the reflector.

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Exchanging the brake light and tail light bulb

Remove the cap

on the underside of the license plate retainer.

Turn the lamp socket

approximately 30° counterclockwise and pull it out

of the tail light housing.

Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it

out of the socket.

To mount the lamp reverse the worksteps indicated above.

Cooling system

Coolant is circulated by a water pump located in the engine. When the

engine is cold the cooling liquid circulates only through the cylinder and the

cylinder head. After the engine has reached its operating temperature

(about 70°C, 158°F), the thermostat opens and the cooling liquid is also

pumped through both aluminum radiators.

Air blowing in through the radiators cools the cooling liquid. The slower the

speed of the motorcycle, the less the cooling liquid is cooled down. Dirty

radiator fins also reduce the cooling efficiency.

If little or no air blows through the radiators, for example when riding

through slow traffic or waiting at traffic lights, the coolant temperature will

rise. If the coolant temperature rises to 85° C (185°F), the fan 3on 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 COOLING LIQUID TEMPERATURE WARNING LIGHT 4 WILL BEGIN TO LIGHT UP,

IF THE COOLING LIQUID TEMPERATURE REACHES APPROX. 105°C (223°F) AND

HENCEFORTH HAS EXCEEDED ITS NORMAL OPERATING TEMPERATURE.

POSSIBLE CAUSES:

– SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE:

IF POSSIBLE INCREASE YOUR RUNNING SPEED, SO THAT MORE AIR CAN BLOW

THROUGH THE RADIATORS. SHOULD THE WARNING LIGHT STILL BE ON OFF AFTER

300 METERS, STOP IMMEDIATELY, SWITCH OFF THE ENGINE AND LOOK FOR OTHER

POSSIBLE CAUSES.

– TOO LITTLE COOLING LIQUID IN THE SYSTEM:

LET THE ENGINE COOL DOWN, AND CHECK THE SYSTEM FOR LEAKAGE’S. ALSO

EXAMINE THE COOLING LIQUID LEVEL CAUTION SCALDING HAZARD! DO NOT

DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. GO TO

YOUR NEAREST KTM GARAGE AND GET IT SEEN TO. IF YOU DRIVE WITH THE

COOLING LIQUID TEMPERATURE WARNING LIGHT ON, YOU WILL CAUSE EVEN MORE

DAMAGES TO THE ENGINE.

– THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING:

THE COOLING FAN MUST BE RUNNING, WHEN THE COOLING LIQUID TEMPERATURE IS

105°C (223°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORKING, AND THERE

APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY THING YOU CAN DO IS TO

DRIVE ON TO YOUR NEAREST KTM GARAGE AT THE LEAST POSSIBLE ENGINE LOAD.

– EXCESSIVE USE OF THE CLUTCH AT SLOW SPEED

WARNING

IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT, USE A RAG TO COVER THE CAP

AND OPEN SLOWLY TO RELEASE PRESSURE.

A mixture of 40% antifreezer and 60% water is used as cooling liquid.

How-ever, the anti-freeze protection must be at least -25° C (-13° F). Aside

from antifreezing protection, this mixture also provides great corrosion

protection which is why it must not be replaced by pure water.

CAUTION

FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (SHELL ADVANCE

COOLANT). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND

COOLANT FOAMING.

Pressure induced by heating of the cooling liquid in the cooling system is

controlled by a valve in the radiator cap 5; a water temperature rising up to

120° C (248° F) is admissible, without fear of problems.

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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.

10 mm

WARNING

when engine is cold

IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT, USE A RAG TO COVER THE CAP

AND OPEN SLOWLY TO RELEASE PRESSURE.

Cleaning the air filter *

It is very important for the engine's life expectancy to clean the air filter

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. Products required for a professional maintenance of the air

filter are available from TWIN AIR. Press out the water from the air filter –

but do not wring – and allow the filter to dry. Lubricate the dry air filter

thoroughly with high-grade filter oil, rubbing to coat the entire filter

surface.

Clean the filter box and cover and check the carburetor connection boot for

damage.

Mount the air filter on the filter holder, position in the filter box (make sure

to center) and fix with the retaining clip. Check whether the air filter is

positioned correctly and mount the filter box cover.

CAUTION

– DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE

THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER

MAINTENANCE. FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER.

– DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS

NOT MOUNTED CORRECTLY.

Adjust idling speed *

Use the adjusting screw

to adjust the basic position of the throttle valve

and, thus, the idle speed.Turning in clockwise direction will increase the

idling speed, turning in counterclockwise direction will reduce the idling

speed. Normal idling speed 1400 - 1500 rpm.

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Adjusting the throttle cable *

When starting to turn the throttle grip, you should feel an initial backlash of

3-5 mm.

3-5 mm

If a correction is necessary, start by removing the tank. Slide back the

protection cover 1. To set the backlash, loosen the counter nut 2and turn

the adjusting screw 3 accordingly. Then, fasten the counter nut and slide

the protection cover back on.

Make sure that the throttle grip will return to the idle position automatically

once you let go of it.

To check the correctness of this setting, start the engine, turn the handlebar

left and right, in both cases as far as it will go. This must not cause any

changes in idling speed. Otherwise, you have to increase the backlash of

the throttle cable.

Draining the carburetor float chamber *

Following every wet-cleaning procedure, the float chamber of the

carburetor should be drained in order to remove any water that may have

penetrated into it. Water in the float chamber causes engine malfunction.

Carry out this job with the engine being cold.

Close the fuel tap.

Put one end of the hose 4 that leads downward behind the engine into a

collecting vessel.

Open the drain plug 5 (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

FUEL IS HIGHLY FLAMMABLE AND TOXIC. BE EXTREMELY CAUTIOUS WHEN HANDLING

FUEL. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN FIRE OR BURNING

CIGARETTES. ALWAYS ALLOW THE ENGINE TO COOL DOWN FIRST. WIPE UP ANY SPILT

FUEL IMMEDIATELY. MATERIALS SATURATED WITH FUEL ARE HIGHLY FLAMMABLE, AS

WELL. IF YOU HAVE ACCIDENTALLY SWALLOWED FUEL OR IF IT HAS GOTTEN INTO YOUR

EYES, GO SEE A PHYSICIAN IMMEDIATELY.

Adjusting the clutch cable

When the engine is cold, the play at the clutch lever should be 1–3 mm

(0.04–0.12 in) (measured at the outer edge).

To adjust the clutch cable turn the adjusting nut 6accordingly.

1-3 mm

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Checking and adjusting the choke cable play *

The choke lever must always have a play of approx. 4 mm (0,16 in).

Remove the seat and tank to adjust.

4 mm

Push the choke lever all the way to the front and slide the protecting cap 1

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.

25 mm

CAUTION

IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER, THIS CAN RESULT IN ENGINE

DAMAGE.

NOTE:

No adjustment need be made to the automatic decompressor.

Engine oil

Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or sur-

passing the quality requirements of API classes SG or SH (see specifications

on the container).

API: SG, SH

TEMPERATUR

CAUTION

0°C

INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE.

–

ꢀ

ꢁ

32°F

10W 40

10W 50

15W 40

15W 50

Checking engine oil level

Allow the engine to run at idle speed for about 4 minutes. Turn off the engine

and place the motorcycle on a flat, level surface (center stand). Wait 5

minutes, unscrew and remove the oil dipstick, and wipe it clean with a cloth.

SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN.

The oil level should be between the two marks on the dipstick, however, it

must never rise above the MAX mark. Otherwise, engine oil would get into

the air filter box by way of the engine venting system.

Add engine oil if necessary.

CAUTION

– INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE

ENGINE.

MAX

MIN

– CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE

READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL.

– DO NOT OVERFILL THE ENGINE CASE.

– DO NOT UNDERFILL THE ENGINE CASE.

Finally, check oil system and engine for leaks.

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Oil circuit

The oil pump 1pumps the motor oil past the bypass valve 2and 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 5where 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 8suctions 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 bkalso 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

AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT IS VERY HOT - DO NOT

BURN YOURSELF.

Place the motorcycle on a horizontal surface

Remove the two plugs

and

, and drain oil into a container.

CAUTION

PLUG

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

Remove the screws and the cover . Loosen the fine screen filter

with

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

The screw

must be removed to allow the motor oil to flow out of the

frame breast pipe.

Clean the plugs thoroughly with petroleum and compressed air in order to

remove any metal filings. After the oil has drained completely, clean the

sealing areas and remount the plugs together with their gaskets. Tighten

plug

with 30 Nm and plug

with 20 Nm. Tighten the screw

with

10 Nm. Clean sealing surfaces on the frame breast pipe , fill new fine

screen filter with engine oil, and oil rubber gasket . Replace fine screen

filter and screw it back in place, your bare hand will do.

Remove oil dipstick on the clutch cover, fill with 1,3 litre engine oil and

attach plug again.

CAUTION

– 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}!

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To facilitate bleeding of the oil system, we have added a hose connection

piece and a plastic hose to the set of tools. Take an empty oil can (1 liter)

and drill a 7 mm-diameter hole into the lid. Screw the hose connection

piece into the lid from the outside, and secure it from the inside with the

M8 hexagon nut.

Slip the plastic hose onto the hose connection piece, and you will have your

filling tool.

Fill 0.6 liters of engine oil into the can and remove the plug 1 next to the

steering head. Introduce the plastic hose into the vent hole B, (see page

30) and fill 0.6 liters of engine oil into the frame’s front tube. Remove

plastic hose, start engine, and let it idle (approx. 20 seconds) until oil

escapes at the hole B. As soon as oil starts to escape, turn off the engine,

and mount the plug together with the gasket.

Let the motor run until it warms. Check the oil drain plugs and the fine

screen filter to make sure they are properly sealed. Check the level of the

motor oil. Place the motorcycle on a horizontal surface (main stand) and

wait for 5 minutes. Remove the dip stick and wipe it with a piece of cloth

SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN.

The oil level should be between the two marks on the oil dipstick, however,

it must never rise above the MAX mark.

Otherwise, engine oil would get into the air filter box by way of the engine

venting system.

Add engine oil, if necessary.

CAUTION

– INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE.

– CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE

READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL.

– DO NOT OVERFILL THE ENGINE CASE.

– DO NOT UNDERFILL THE ENGINE CASE.

Afterwards check the entire oil system and motor to make sure they are

properly sealed. Attach the covering of the fine screen filter to the frame

breast pipe.

NOTE: Dispose of used oil properly! Under no circumstances may used oil

be disposed of in the sewage system or in the open countryside. 1 liter oil

contaminates 1.000.000 liter water

Changing oil filter *

Replace the oil filter when changing the engine oil. Press the foot brake

pedal and place a screwdriver or similar between foot brake pedal and

stopper roll so that the oil filter cover is more accessible. Remove banjo bolt

and the three screws. Remove oil filter cover

and oil filter. Clean the

filter case, oil filter cover and sealing areas. Make sure the oil duct in the oil

filter cover is not clogged.

Place the new oil filter 4on 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 (4 ft.lb). Tighten the hollow screw with seals and tighten to 15 Nm

(11 ft.lb).

Finally, start the engine and check the oil system for leakage.

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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

CAUSE

REMEDY

Engine doesn’t crank.

Turn on the ignition, switch the gear to neutral and switch the

emergency OFF switch on.

Operating errror

Discharged battery.

Recharge the battery and investigate the causes for dischar-

ging; contact a KTM dealer.

Defect ignition lock or emergency Check ignition lock and emergency OFF switch, contact a

OFF switch

KTM dealer.

The engine doesn't crank. Blown fuse safe-starting system.

The neutral indicator lamp

Replace fuse (below the headlight mask).

doesn't light up.

Blown main fuse.

Remove seat and replace the main fuse. If fuse blows again

contact a KTM dealer.

The engine cranks only with Defect safe-starting system.

pulled clutch lever

Contact a KTM dealer.

Engine cranks with gear Defect safe-starting system.

engaged.

Contact a KTM dealer.

Engine cranks but doesn’t Operating error

start.

Open fuel tap, tank fuel, you did not use choke i.e. the warm-

start device. Pay attention to starting off information (see

driving instructions).

The motorcycle has been out of The easily inflammable components of the new fuels evapo-

operation for a longer period of rate during longer periods of standstill.

time. Therefore old fuel has accu- When the motorcycle has been out of operation for more

mulated in the float chamber

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.

Fuel supply interrupted

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

Flooded engine

Fully open the throttle when starting or exchange the spark

plug, respectively

Sooty or wet spark plug

Electrode gap too large

Clean and dry the spark plug or exchange it, respectively

Adjust spark plug elektrode gap to 0,9 mm

Spark plug connector or spark plug Dismount spark plug, connect ignition cable, hold to ground

faulty

(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

The plug connection of the CDI- Remove the seat, the right side cover and the fuel tank. Clean

unit, the pulse generator or the the plug connection and treat it with contact spray

ignition coil has oxydized

Water in carburetor or jets blocked Dismount and clean carburetor

Claped out side stand

Faulty side stand switch

Clap up side stand

Renew side stand switch

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CAUSE

REMEDY

TROUBLE

Glogged idling jet

Disassemble carburetor and clean jets

Engine fails to idle

Oncorrect adjustment of adjusting Have carburetor adjusted

screws on carburetor

Defective spark plug

Replace spark plug

Defective ignition system

Have ignition system checked

Carburetor fuel level too high Dismount carburetor and check if worn out

because

Engine does not rev high

Float needle is dirty or worn out

Float leaks

Replace float needle

Replace float

The cold starting system is perma- Adjust choke cable.

nently activated due to a lack of

play in the choke cable.

Defective membrane of slide

Carburetor leaking

Replace membrane

Check vacuum hose and venting hose of carburetor for correct

position (no kinks)

Loose carburettor jets

Tighten jets

Electronic ignition timing faulty

Have ignition system checked

Fuel supply partically interrupted or Clean and check fuel system as well as carburetor

carburetor dirty

Engine will not reach full

power

Float leaks

Replace the float

Defective membrane of slide

Carburetor leaking

Replace membrane

Check vacuum hose and venting hose of carburetor for correct

position (no kinks)

Air filter very dirty

Clean or replace air filter, contact a KTM dealer

Have valve clearance adjusted

Valve clearance to small

Loss of compression because hand Check setting of the hand decompression cable

decompressor has no play

Electronic ignition timing faulty

Insufficient cooling liquid

Have ignition system checked

Refill cooling liquid (see maintenace work), check cooling

system for leaks

Engine overheats

Radiator fins are extremely dirty

Foam forms in cooling system

Bent radiator hose

Clean radiator with water jet

Replace cooling liquid, use antifreezer with brand name

Shorten or replace cooling hose

Thermostat defective

Remove and check thermostat (opening temperature 70°C

(158°F) or replace it, contact a KTM dealer

Blown fan fuse

Defect thermoswitch

Fan defective

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

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CAUSE

REMEDY

TROUBLE

Buckling gear ventilation hose

Engine oil level too high

Readjust or replace ventilation hose

High oil consumption

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

necessary

Engine oil too thin (viscosity)

Use thicker engine oil; see chapter „Engine oil“

Voltage regulator faulty

Blown fuse

Remove seat and check connections. Have voltage regulator

checked

All switched on lamps blown

out

Replace fuse (below the headlight mask).

Replace indicator lamp

Headlight and parking light

fail

Blown fuse

Flasher lights, brake light,

fan and horn fail

Defect indicator lamp.

Defect neutral switch.

The NEUTRAL lamp is not

on even though the gear is

in NEUTRAL

Connect cable to ground; neutral switch must be replaced if

indicator lamp lights up.

Loose connections, defect cable.

Check connections and cables.

The ignition (power consumer) Recharge the battery according to the relevant instructions.

hasn’t been switched off

The battery is discharged

The battery isn’t charged by the Remove seat and check voltage regulator connections; voltage

generator because

regulator and generator should be checked by a KTM dealer.

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CLEANING

Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.

The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The hard

dirt can be removed before with the help of a soft water jet.

CAUTION

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE DISTURBINGS OR LEAD TO A PREMATURE DESTRUC-

TION OF THESE PARTS.

– You should use normal trade-mark detergents to clean the engine. Strongly dirted parts should be cleaned additionally with the

help of a paint brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive

until the engine has reached the working temperature and also use the brakes. Due to the heat, the water also evaporates at the

unapproachable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate.

– After the motorcycle has cooled down, oil and grease all sliding and pivot points. Treat the chain with a chain spray too.

– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, light switch and the socket

connectors with contact spray.

CONSERVATION FOR WINTER OPERATION

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take

precautions against the aggressive road salt.

– clean motorcycle thoroughly and let it dry

– treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion

agent.

WARNING

KEEP 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!

STORAGE

Should you desire to make a pause over a longer space of time, please observe the following instructions:

– Clean motorcycle thoroughly (see chapter: CLEANING)

– Change engine oil, oil filter and fine screen filter (old engine oil contains aggressive contaminations).

– Check antifreezer and amount of cooling liquid.

– Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug of the float chamber

to remove the remaining fuel.

– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in

order to distribute the oil onto the cylinder walls and mount the spark plug.

– Set piston to compression so that the valves will be closed (slowly operate the kickstarter, until you can hear the automatic

decompressor click (release)

– Let fuel flow out of tank into an appropriate container.

– Correct tire pressure.

– Lubricate pivot points of the control levers, foot rests, etc. as well as the chain.

– Service the shock absorber linkage

– Disassemble and charge battery (see chapter: BATTERY).

– The storage place should be dry and not subject to excessive temperature fluctuations.

– Cover the motorcycle with 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.

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TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002

640 LC4

640 LC4 Supermoto

Central chrome-moly-steel frame

Frame

Fork

White Power – Up Side Down 4357 MXMA

Wheel travel front/rear

Rear suspension

Front brake

270 / 300 mm (10,6 / 11.8 in)

Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing

Disc brake with carbon-steel brake disc, brake caliper floated

Front brake disc

Rear brake

Ø 300 mm (11.8 in)

Ø 320 mm (12.6 in)

Disc brake with carbon-steel brake disc ꢂ 220 mm (8.7 in), brake caliper floated

Tyres front

90/90-21

120/70-17

2.0 bar (29 psi)

2.2 bar (31 psi)

160/60-17

Air press. road, driver only

Air press. road with passenger

Tyres rear

1.8 bar (26 psi)

2.0 bar (29 psi)

140/80-18

Air press. road, driver only

Air press. road with passenger

Fuel tank capacity

2.0 bar (29 psi)

2.2 bar (31 psi)

2.4 bar (34 psi)

11 or 18 liter (2.9 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve

Final drive ratio 16:42t 17:42t

Chain

Bulps

X – Ring 5/8 x 1/4"

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

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

instrument lights . . . . . . . . 12V 1,2W (socket W2x4,6d)

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)

maintenance-free battery 12V 8Ah

Battery

Steering angle

62,5 °

63°

Wheel base

1510 10 mm (59.4 0.4 in)

Seat high

940 mm (37.6 in)

355 mm (14.0 in)

136kg (300 lbs)

910 mm (36.4 in)

335 mm (13.2 in)

137 kg (302 Ibs)

Ground clearance

Dead weight without fuel

Max. permissible front axle load

Max. permissible rear axle load

Max. permissible laden weight

211 kg (465 lbs)

335 kg (740 lbs)

350 kg (773 lbs)

STANDARD ADJUSTMENT - FORK

STANDARD-ADJUSTMENT - SHOCK ABSORBER

640 LC4

SUPERMOTO

WP 0518W722

640 LC4

SUPERMOTO

WP 0118W721

WP 0518W714

WP 0118W724

Compression adjuster

Rebound adjuster

Spring

Compression adjuster

Rebound adjuster

Spring

4,2 N/mm

6 mm (0,24in)

150 mm (5,9in)

SAE 5

5,0 N/mm

9 mm (0,36in)

130 mm (5,1in)

SAE 5

66 / 260

23,5 mm(0,94in)

75 / 260

15 mm(0,6in)

Spring preload

Air chamber length

Fork oil

Spring preload

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TIGHTENING TORQUES - CHASSIS LC4

Collar nut front axle

Collar nut rear axle

Shock absorber top

M16x1,5

M20x1,5

M10

M6 (10.9)

M12

M14x1,5

M10

40 Nm

80 Nm

45 Nm

(30ft.lb)

(59ft.lb)

(33ft.lb)

(7ft.lb)

(19ft.lb)

(44ft.lb)

(74ft.lb)

(33ft.lb)

(19ft.lb)

(25ft.lb)

(74ft.lb)

(15ft.lb)

(11ft.lb)

(7ft.lb)

Shock absorber bottom

Collar screws brake disk front/rear

Screw brake caliper front

Bearing bolt linkage arm/frame

Collar nuts rocker arm bolts

Engine mounting screw

Ball joint for push rod

Sprocket screws on nuts

Collar nut swingarm bolt

Clamping screws top triple clamp (USD 43)

Clamping screws bottom triple clamp (USD 43)

Clamping screws fork stubs

45 Nm

Loctite 243 + 10 Nm

Loctite 243 + 25 Nm

60 Nm

100 Nm

45 Nm

Loctite 243 + 25 Nm

Loctite 243 + 35 Nm

100 Nm

M14x1,5

20 Nm

15 Nm

10 Nm

Screws handlebar clamp

Allan head screw handle bar support

Spoke nipple

M10

Loctite 243 + 20 Nm

4 Nm

(15ft.lb)

(3ft.lb)

Other screws on chassis

10 Nm

(7ft.lb)

M10

25 Nm

45 Nm

15 Nm

30 Nm

(19ft.lb)

(33ft.lb)

(11ft.lb)

(22ft.lb)

(37ft.lb)

Other collar nuts on chassis

50 Nm

TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 SUPERMOTO 2002

BASIC CARBURETOR SETTING

640 LC4

640 LC4 Supermoto

Type

BST40-225

090298

142,5

Carb.-setting number

Main jet

Needle jet

689 X-6

Idling jet

Jet needle

6G5

Needle clip pos. f. top

Mixt. adj. screw open

3. from top

2,25

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Engine

640 LC4

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter

Displacement

Bore / Stroke

Ratio

624,6 ccm

101 / 78 mm

11 : 1

unleaded premium gasoline with a least RON 95

4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain

249/1

Fuel

Valve timing

Camshaft

Valve diameter

Valve clearence cold

Crank shaft bearing

Connecting rod bearing

Top end bearing

Piston

Intake: 36 mm

Exhaust: 30 mm

0,15 mm Exhaust: 0,15 mm

2 cylinder roller bearing

needle bearing

bronze bushing

forged/cast aluminium alloy

1 compression ring, 1 taper face ring, 1 oil scraper ring

two Eaton-oilpumps

Piston rings

Engine lubrication

Engine oil

see bellow #

Engine oil quantity

Primary ratio

Clutch

appr. 2,1 liters including frame

straight geared spur wheels 30 : 81 teeth

multi disc clutch in oil bath

5-speed claw shifted

Transmission

Gear ratio

1st

2nd

3rd

4th

5th

14:35

15:24

18:21

20:19

22:18

Ignition system

Ignition timing

Generator

contactless DC-CDI ignition with digital advanced system type KOKUSAN

adjustment to max. 38° BTDC at 6000 rpm

12V 200W

Spark plug

NGK DPR8 EA9

0,9 mm

Spark plug gap

Cooling system

Cooling liquid

Starting equipment

liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump

1liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)

electric starter and kickstarter

Engine oil

Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or

API: SG, SH

surpassing the quality requirements of API classes SG or SH (see specifica-

tions on the container).

CAUTION

TEMPERATUR

0°C

32°F

POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.

–

ꢀ

ꢁ

10W 40

10W 50

15W 40

15W 50

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HEAD WORD INDEX

page

Adjisting of free travel at the hand brake lever....................19

Adjusting idling speed.........................................................28

Adjusting the choke cable...................................................30

Adjusting the clutch cable...................................................29

Adjusting the throttle cable.................................................29

Battery................................................................................25

Chain maintenance.............................................................18

Chain wear .........................................................................19

Changing oil filter ..............................................................32

Changing the basic position of the foot brake pedal ...........20

Changing the fine screen filter ............................................31

Changing the spring preload of the shock absorber ............17

Charging the battery...........................................................25

Chassis number.....................................................................4

Check the rear brake fluid level...........................................21

Checking and adjusting steering head bearing ....................17

Checking chain tension.......................................................18

Checking of brake fluid level - front brake ..........................20

Checking rubber ring on the rear shock absorber................18

Checking spoke tension ......................................................24

Checking the adjustment of the hand decompression cable 30

Checking the cooling liquid level.........................................28

Checking the engine oil level ..............................................30

Checking the front brake pads............................................20

Checking the rear brake pads..............................................21

Checking the shock absorbtion rubbers in the rear hub.......23

Choke lever ..........................................................................5

Cleaning .............................................................................36

Cleaning the air filter ..........................................................28

Clutch lever ..........................................................................4

Combination switch..............................................................6

Compression damping of fork...............................................8

Compression damping of shock absorber..............................8

Conservation for Winter Operation.....................................36

Consumer Information for USA only ..................................40

Cooling system ...................................................................27

Correct chain tension..........................................................18

Dismounting and mounting the front wheel .......................22

Dismounting and mounting the rear wheel.........................23

Draining the carburetor float chamber ................................29

Driving Instructions...............................................................9

Engine number, engine type .................................................4

Engine oil............................................................................30

Exchanging the brake light and tail light bulb......................27

Exchanging the headlight lamp...........................................26

Filler cap ...............................................................................6

Foot brake pedal...................................................................7

Fuel ......................................................................................6

Fuel tap ................................................................................7

Fuses for individual power-consuming units........................26

General information on KTM disc brakes ............................19

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

Hand decompression lever....................................................4

Head word index ................................................................43

Holding bars .........................................................................8

Ignition lock..........................................................................5

Kickstarter.............................................................................7

Lubricate shock absorber linkage ........................................17

Main fuse ...........................................................................26

Maintenance work on chassis and engine ...........................16

Oil and fine screen filter change, bleeding of the oil system 31

Oil circuit............................................................................31

Operation Instruments..........................................................4

Periodic Maintenance- Schedule .........................................14

Re-initation after time of storage ........................................36

Rebound damping of fork.....................................................8

Rebound damping of shock absorber....................................8

Refilling the front brake fluid reservoir ................................20

Refilling the rear brake fluid reservoir..................................21

Removing the seat..............................................................16

Replacing the parking light bulb..........................................26

Serial number locations.........................................................4

Shift lever .............................................................................7

Speedometer, indicator lamps...............................................5

Starter tip switch, emergency OFF switch..............................6

Storage ..............................................................................36

Technical spezifications- engine ..........................................38

Technical spezifications- chassis ..........................................37

Tires, air pressure................................................................24

Tool set...............................................................................16

Trouble shooting.................................................................33

wiring diagram.........................................................Appendix

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