KTM Motorcycle 640 LC4 ENDURO User Manual

BEDIENUNGSANLEITUNG2004

640 LC4 ENDURO

640 LC4 SUPERMOTO

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART.NR: 3.210.85

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Introduction

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

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring

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

Before you go for your first ride, be sure to read this manual carefully and thoroughly in

order to familiarize yourself with how to operate your new motorcycle and with its

characteristics, even if this means that you will have to dedicate some of your valuable

time to this task. Only by doing so will you learn how to tune your motorcycle to your

specific needs and how to protect yourself against injury. Besides, this manual contains

important information on motorcycle maintenance. At the time this manual was typeset,

it was up-to-date with the latest state of this production series. It cannot be completely

ruled out, however, that minor discrepancies may exist resulting from further design

upgrades of these motorcycles.This manual is an important part of your motorcycle and

should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance

work on the chassis and engine" must be performed. If maintenance work should

become necessary during a competition it should be performed by a trained mechanic.

KTM strongly recommends that all service work to your KTM should be performed by a

qualified KTM dealer.

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

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

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

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

To ensure that all work to your KTM is performed properly and to avoid warranty

conflicts, KTM recommends that you always have your KTM serviced by a recognized

and qualified KTM dealer.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to

enjoy it to the full. It may, however, involve potential problems for the environment or

lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle

is used responsibly. To safeguard the future of motorcycle sports, make sure that you use

the motorcycle in accordance with the law, show that you are environmentally conscious

and respect the rights of others.

We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

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IMPORTANT LIMITED WARRANTY AND

LIMITED GUARANTEE INFORMATION

The 640 LC4 Enduro model was designed to resist the usual wear and tear of

normal use on the road and easy terrain (unpaved roads).

The 640 LC4 Supermoto model is designed for regular on-road service but

not for use off of paved roads.

The service, care and operating instructions for the engine and chassis

specified in the owner's manual must be observed to ensure that the bike

runs smoothly and to avoid premature wear.

The service work specified in the "Lubrication and Maintenance Schedule"

must be performed and service records must be kept for warranty

documentation. Lack of proper service and maintenance records or

documentation could void warranty.

The fuels and lubricants specified in the owner's manual or those of an equal

quality must be used in accordance with the maintenance schedule.

The warranty or guarantee shall become void for damage and consequential

damage caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely

muddy and wet terrain, can lead to higher than average wear on

components such as the drive train or the brakes. In this case it may become

necessary to service or replace wear parts before the service limit specified in

the maintenance schedule has been reached.

No warranty will be assumed if the bike is used in races or competitions.

In accordance with the international quality management

ISO 9001 standard, KTM uses quality assurance processes

that lead to the highest possible product quality.

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INDEX

Page

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

Page

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

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

Changing the basic position of the handbrake lever........26

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

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

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

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

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

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

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

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

Dismounting and mounting the front wheel

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Checking the adjustment of the hand decompression cable ..37

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GENERAL TIPS AND WARNINGS FOR STARTING THE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Changing the spring preload of the shock absorber........22

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

Checking rubber ring on the rear shock absorber............22

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

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

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

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

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

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

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

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

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

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

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SERIAL NUMBER LOCATIONS

Chassis number

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

Write this number into the relevant area on page 1.

Engine number, engine type

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

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

area on page 1.

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1is located on the left side of the handlebar. The adjusting

screw A is used to change the original position of the clutch lever (see

maintenance work on chassis and engine).

Hand decompression lever

The hand decompression lever 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.

Hand brake lever

The hand brake lever 3 is mounted on the handlebars on the right and

actuates the front wheel brake. The adjusting screw B can be used to

change the basic position of the hand brake lever (see "Maintenance").

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Multi-functional digital speedometer

The universal instrument is divided into 3 parts.

Use the MODE and SET 1button to change the display and the basic set-

tings in the display.

Display 2 shows all of the information that may be of interest to you. 5

display modes can be selected with the MODE button.

The indicator lamps 3 provide additional information on the motorcycle's

running condition.

Display

TEST

When you switch on the ignition, all of the display elements will light up for

1 second for the function test.

TEST

WS (wheel size)

The display will change and show the diameter of the front wheel in inches

for 1 second (WS = wheel size).

Then the CLOCK mode will be displayed, or the mode that was active

when the ignition was switched off.

CLOCK

You will recognize the OK display by the blinking dots between the hours

and minutes. It displays the speed, temperature of the cooling liquid and

the clock.

CLOCK

ODO

To switch to the next display mode, press the MODE button.

ODO

The speed, temperature of the cooling liquid and the total kilometers or

miles traveled are shown in the ODO mode.

To switch to the next display mode, press the MODE button.

TRIP 1

The TRIP 1 mode shows the speed, the temperature of the cooling liquid

and the trip odometer 1.

TRIP 1

TRIP 2

TRIP F

To switch to the next display mode, press the MODE button.

TRIP 2

The TRIP 2 mode shows the speed, the temperature of the cooling liquid

and the trip odometer 2.

To switch to the next display mode, press the MODE button.

TRIP F

The TRIP F (fuel) mode shows the speed, the temperature of the cooling

liquid and the distance traveled since reaching the low-fuel mark (the low-

fuel indicator lamp will blink).

To return to the UHR mode, press the MODE button.

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Setting options in the display

KILOMETERS OR MILES.

10 sec

You can have the speed and distance shown in kilometers or miles in the

display. The display can be adapted to the respective country on long-

distance trips.

To switch from kilometers to miles, switch on the ignition and press the

MODE 1 button for approx. 10 seconds. The km/h display will switch to

mph. The speed and the stored distances will be converted and displayed in

miles.

To return to kilometers, proceed as described above.

CLOCK

Switch on the ignition and change to the CLOCK mode.

Simultaneously press MODE 1 and SET 2. The numbers on the clock will

start to blink. Use the MODE button to set the hours and the SET button to

set the minutes.

The press the MODE and SET buttons simultaneously.

NOTE: 0:00 will be displayed if the clock is not supplied with electricity. This

can be caused by a defective fuse or a fault in the board electric system (see

Troubleshooting).

TRIP 1

The trip meter 1 runs continuously and counts up to 999.9. It can be used

to measure the length of a certain route on a trip or the distance between

two refueling stops.

To return the trip meter 1 to zero, switch on the ignition, change to the

TRIP 1 mode and press the SET button.

RESETTING TRIP 2

The trip meter 2 runs continuously and counts up to 999.9. It can be used

similarly to TRIP 1 or together with a switch available as an accessory (see

below) for trips according to a roadbook.

To return the trip meter 2 to zero, switch on the ignition, change to the

TRIP 2 mode and press the SET button.

NOTE: A Tripmaster switch (Part no. 582.14.069.044) is available as an

accessory and enhances the trip meter 2 functions. You can correct the

displayed route by increasing or decreasing in increments of 0.1. For

example, if you have taken the wrong road when driving according to a

roadbook, you can easily correct the display to correspond to the roadbook

again. It can also be used to change the display modes. The switch is moun-

ted on the handlebars so that you can keep your hands on the handlebars.

TRIP F

When the fuel level reaches the reserve mark, the display will automatically

switch to TRIP F and begin to count (no matter which display mode was

active before). At the same time, the fuel warning lamp will start to blink.

You will still have enough reserve fuel for at least 35 kilometers.

After refueling, it will take approx. 3 minutes for TRIP F to automatically

reset to 0 and return to the previous display mode.

NOTE: To use up the reserve fuel in the tank, move the fuel cock to the RES

position by hand.

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Cooling liquid temperature display

The temperature display 1is shown in 7 bars. The more bars that light up,

the hotter the cooling liquid. When the lowest bar lights up, the cooling

liquid has reached a temperature of approx. 40°C (104°F). When the upper

bar lights up 120°C (248°F), all of the bars will start to blink and the red

warning lamp 2will light up.

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

WARNING

P^{OSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE}, CAUSING THE RED WARNING LIGHT

^{FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP}:

– D^{RIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES}

– N^{OT ENOUGH COOLING LIQUID IN THE SYSTEM}

– T^{HE VENTILATOR ON THE RADIATOR IS NOT RUNNING}

– IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY

Indicator lamps

The green indicator lamp will blink in the blinker rhythm when the

blinker is switched on.

NOTE:

The indicator lamp will blink slower when a blinker is broken.

The green indicator lamp will light up when the gearbox is in an

idling position.

The blue indicator lamp will light up when the high beams are

switched on.

The red warning lamp will start to blink when the cooling liquid

reaches 120°C (248°F).

This warning light has no function.

This indicator lamp has no function.

Choke lever

If the choke lever 3 is pulled backwards, a bore will be opened in the

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

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

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

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

Ignition lock with 3 switch positions

Switch positions of ignition lock 4:

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

= Ignition on, (engine can be started)

= Ignition off, handlebar blocked

To switch the ignition to position

turn the ignition key to position

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

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

The ignition key can be withdrawn in position

and

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Combination switch

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

= High-beam light

= Low-beam light

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

The indicator switch 3 returns to central position after actuation.

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

The horn is sounded with button 4.

Starter tip switch, emergency OFF tip switch, light switch

The emergency off switch 5 is provided for emergency situations and

should not be used to switch off the engine.

The engine is ready for operation in position

circuit are switched on).

The engine cannot be started in position

circuit are interrupted).

(ignition circuit and starter

The light switch has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch 6to operate the electric starter.

Filler cap

The filler cap 7 can be locked and is provided with a fuel evaporation

control system.

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

lift off the filler cap.

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

and take out the key.

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Fuel tap

OFF In this position the fuel tap is closed. No fuel may flow to the

carburetor.

ON When using the motorcycle, the twist grip must be set to the ON

position. Now fuel may flow to carburetor. In this position the tank

empties down to the fuel reserve of approx. 2.5 liters.

RES The reserve, approximately 2.5 liters, cannot be tapped until the twist

grip is turned to the RES position. Fill the tank as soon as possible and

remember to turn the twist grip back to the ON position so that you

will have backup fuel next time, too.

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.

Foot brake pedal

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

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

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Compression damping of fork

The compression damping is to be set at the lower end of the fork tubes. It

only regulates the degree of damping during compression. Remove closing

cap A. By using the knob 1 (COM), the degree of damping of the

compression can be adjusted. Turn the knob clockwise to increase damping,

turn it counterclockwise to reduce damping during compression.

BASIC SETTING:

– turn rotary knob clockwise as far as it will go

– turn it back counter-clockwise by as many clicks as are specified for the

relevant type of fork

WP 0518Y737.............20 Klicks

WP 1418Y750.............20 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 0518Y737.............12 Klicks

WP 1418Y750.............15 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 0118Y734.............Position 3

WP 0118Y733.............Position 4

(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 0118Y734.............Position 7

WP 0118Y733.............Position 8

(640 LC4)

(640 LC4 Supermoto)

WARNING

T^{HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED}

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

^{MAINTENANCE WORK YOURSELF}. SEVERE INJURIES COULD BE THE RESULT.

Holding bars

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

vehicle.

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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

WARNING

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read these operating instructions carefully before your first

ride.

– W^{EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE}. C^LEVER

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

COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS

^POSSIBLE. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE

^CLOTHING.

– Enter the chassis, engine and key numbers on page 1.

– Familiarize yourself with the operating elements.

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

most comfortable position.

– Get used to handling the motorcycle on an empty parking

lot or open space, before starting on a longer drive. Also try

to drive as slowly as possible and in standing position, to

improve your feeling for the vehicle.

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

abitily and experience.

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

the foot rests while driving.

– D^{O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL}.

– A^{LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS}

^{BECOME AWARE OF YOU AS EARLY AS POSSIBLE}.

– O^{NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY}KTM. FOR

EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF

THE ^MOTORCYCLE. CASES, ^EXTRATANKS ETC. CAN ALTER THE

WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING

^PROPERTIES.

– T^{HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY}

^{WITH TIRES THAT HAVE THE SAME PROFILE TYPE}.

–

Remove your foot from the foot brake lever when you

are not braking. If the foot brake lever is not released the

brake pads rub continuously and the braking system is

overheated.

– N^{EW WHEELS HAVE A SMOOTH SURFACE}, WHICH MEANS THAT THEY

^{MUST BE RUN IN TO ACHIEVE FULL GRIP}. FOR THIS PURPOSE, RIDE THE

MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST

200 KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT

DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY

^ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL GRIP

^{CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN}.

– D^{RIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF}

EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY

^{OPERATING TEMPERATURE}. M^{AXIMUM ROAD GRIP IS ASSURED WHEN}

THE TIRES ARE WARM.

– 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

– O^{BSERVE THE TRAFFIC REGULATIONS}, DRIVE DEFENSIVELY AND TRYING

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

^{RECOGNIZED AS EARLY AS POSSIBLE}.

– Luggage

– C^{HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND}

–

Driver with protective clothing and helmet.

^{YOUR DRIVING SKILLS}.

– Pay attention to running-in procedure.

– D^{RIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS}.

–

RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR

GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY

^SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

^GOGGLES, THE OPERATOR WILL BE BLINDED.

Running in the LC4 models

Even very precisely machined sections of engine components

have rougher surfaces than components which have been

sliding against one another for quite some time. Therefore,

every engine needs to be broken in. For this reason, during its

first 1000 kilometers (620 miles) the engine must not be

revved up to its performance limits. The engine speed of 4800

r.p.m. must not be exceeded during the first 1000 kilometers

(620 miles). During this break-in time, you should ride your

motorcycle in different conditions (roads, easy off-road

terrain). The following table shows you the maximum velocity

values in the different gears at 4800 r.p.m. as based on the

rear wheel transmission ratio of your motorcycle.

– N^{EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE}

^{ENGINE IS RUNNING}.

Accessories and payload

Accessory parts and baggage can significantly decrease a

motorcycle's driving stability. Please observe the following

warnings.

WARNING

– N^{EVER DRIVE FASTER THAN}130 ^KPH(80 ^MPH) IF YOU HAVE MOUN-

TED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY PARTS

^{CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE}'S HANDLING, ESPECI-

ALLY IN THE MAXIMUM SPEED RANGE.

– N^{EVER DRIVE FASTER THAN}130 KPH (80 MPH) IF YOUR MOTORCY-

^{CLE IS LOADED WITH CASES OR OTHER BAGGAGE}. THEY WILL IMPAIR

THE MOTORCYCLE'S HANDLING AT HIGHER SPEEDS AND CAN EASILY

CAUSE IT TO GO OUT OF CONTROL

ratio

625 LC4

16:42 Z

LC4 SUPERMOTO

17:42 Z

gear

1. G

2. G

3. G

4. G

5. G

35 kmh

50 kmh

70 kmh

90 kmh

100 kmh

35 km/h

55 km/h

75 km/h

90 km/h

100 km/h

– I^{F YOU HAVE CASES MOUNTED}, DO NOT EXCEED THE MANUFACTU-

RER'S RECOMMENDED MAXIMUM PAYLOAD.

– F^{ASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTORCYCLE}

AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR

^{WHEELS AND ON THE LEFT AND RIGHT}.

– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND; LOOSE

^{BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY}.

– A ^{HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE}'S HANDLING AND

CONSIDERABLY INCREASE THE BRAKING ^DISTANCE; ADAPT YOUR

^{DRIVING SPEED ACCORDINGLY}.

NOTE: D^{URING THE STAGE OF RUNNING THE ENGINE IN}, THAT IS THE

^FIRST1000 KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF A

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

^REPAIRED.

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DRIVING INSTRUCTIONS

Check the following before each start

When you start, the motorcycle must be in perfect mechanical condition.

For safety reasons, you should make a habit of performing an overall check

of your motorcycle before each start.

The following checks should be performed:

1 CHECK OIL LEVEL

Insufficient oil results in premature wear and consequently to engine

damage.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap,

check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain

can tear, and insufficient lubrication can result in unnecessary wear of

chain and chain wheels.

4 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced.

The tread depth must comply with the legal regulations. Also check the

air pressure. Insufficient tread and incorrect air pressure deteriorate the

driving performance.

5 BRAKES

Check correct functioning of the braking system. Check for sufficient

brake fluid in the reservoir. The reservoirs have been designed in such a

way that brake fluid does not need to be refilled even when the brake

pads are worn. If the level of brake fluid falls below the minimum value,

this indicates a leak in the braking system or completely worn out brake

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

as complete failure of the braking system can be avoided.

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

linings.

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

6 CABLES

Check correct setting and smooth operation of all control cables.

7 COOLING FLUID

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

8 ELECTRICAL SYSTEM

Check correct operation of headlamps, tail-lights, brake lights, indicators,

control lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

10REAR MIRROR

Sit on the motorcycle and check the adjustment of the rear mirror.

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Starting when the engine is cold

1 Open the fuel tap 1

2 Switch on ignition (turn ignition key 2into position ).

3 Switch on emergency OFF switch 3.

4 Switch transmission to idle (green indicator lamp N 4lights up).

5 Operate cold starting device (choke) 5.

6 Do not accelerate; operate starter button 6.

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

engine runs unevenly.

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

WARNING

– T^OAVOID INJURIES, ^ITIS RECOMMENDED TO WEAR BOOTS WHEN USING THE

^KICKSTARTER.

– D^{O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM}. E^XHAUST

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

A^{LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING}.

CAUTION

– M^AXIMUMPERIOD FOR CONTINUOUS STARTING: 5 ^SECONDS. WAIT AT LEAST

5 ^{SECONDS BEFORE TRYING AGAIN}.

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

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

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

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

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE

STARTER TIP SWITCH:

– the transmission is switched to idle

– Check if the emergency OFF switch is on

– Check if the ignition is on

– the headlight is on.

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

– If the lights are on, proceed as described in the „Trouble-shooting“

section or contact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE

THE STARTER TIP SWITCH:

– Check if the fuel tap is open

– Check if the choke lever has been operated

– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank

– if sufficient fuel is in the tank, proceed as described in the „Trouble-

shooting“ section or contact a KTM dealer.

NOTE LC4 / LC4 SUPERMOTO:

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

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

is pulled, respectively.

Motorcycles with side stands are also equipped with a safety starting

system.

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

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

Starting when the engine is warm or hot

1 Open the fuel tap 1

2 Switch on ignition (turn ignition key 2into position ).

3 Switch on emergency OFF switch 3.

4 Switch transmission to idle (green indicator lamp N 4lights up).

5 Do not accelerate; operate starter button 6.

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

What to do when the engine is „flooded”

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

plug.

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CAUTION

Kickstart instructions

Be sure to kick up the side stand before you start the engine to

avoid any damage.

– 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.

Start as described above, then push the kickstarter hard ALL

THE WAY.

WARNING

– W^{HEN STARTING THE ENGINE}, MAKE SURE THAT YOU ALWAYS WEAR

^{STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY}. YOU

^{MIGHT SLIDE OFF THE KICKSTARTER}, OR THE ENGINE MAY CAUSE THE

^{KICKSTARTER TO RECOIL}, THEREBY CAUSING INJURIES TO FOOT AND

^LEG.

– N^{EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO}

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}.

–

^{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}.

– L^{ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN}

^{LEAD TO ENGINE DAMAGE}.

– N^{EVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER}. OTHERWISE

^{DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR}.

CAUTION

–

THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT

^{TEMPERATURE HAS REACHED}120°C.

B^{EFORE YOU ACTUATE THE KICKSTARTER}, BE SURE TO KICK UP THE SIDE

^STAND.

^{POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE}:

-^{LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR}

TEMPERATURES

-LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT

-FAN AT LEFT RADIATOR IS NOT RUNNING

-IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES

PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY, SO

THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ^ESCAPE.

- CAUTION SCALDING HAZARD! - ^{AND CHECK THE COOLING}

^{LIQUID LEVEL}.

Starting off

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

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

WARNING

B^{EFORE YOU START OFF}, CHECK THAT THE MAIN STAND HAS BEEN SWUNG

^{UP FULLY}. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN

^{GO OUT OF CONTROL}.

D^{O NOT DRIVE ON}, UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING

^SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS AS SOON AS

^{POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED}.

– I^{F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING}, CHECK THAT

Shifting/Riding

^{THE ENGINE FASTENING BOLTS ARE TIGHT}.

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.

– I^{N THE EVENT THAT}, WHILE RIDING ON YOUR MOTORCYCLE, YOU

^{NOTICE ANY UNUSUAL OPERATION}-^{RELATED NOISE}, ^{STOP IMMEDIA}-

^TELY, ^{TURN THE ENGINE OFF}, ^{AND CONTACT AN AUTHORIZED}KTM

DEALER.

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, for example, the engine stalls at an intersection, simply pull

the clutch lever and start. You do not need to shift into the

neutral position.

When driving downhill, use the braking effect of the engine.

Change down one or two gears but do not overspeed the

engine. In this way, you will not need to brake so much and

the brakes will not overheat.

WARNING

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

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

^{THE BRAKES MUST BE BRAKED DRY}.

– O^{N SALT}-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED

^{AS WELL}. FIRST, THE BRAKES MUST BE BRAKED CLEAN.

– W^{HEN YOU BRAKE}, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER

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

^{WEAKER THE BRAKING EFFECT}. IN EXTREME CASES, THE ENTIRE BRAKING

^{SYSTEM CAN FAIL}.

WARNING

– A^{VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND}

^{ON WET OR SLIPPERY GROUND}. OTHERWISE YOU MIGHT EASILY LOSE

CONTROL OVER YOUR MOTORCYCLE.

–

WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION

LOCK TO POSITIONS AND

– D^ONOT TRY TO CHANGE THE SETTINGS WHILE DRIVING. YOUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE

^{YOU TO LOSE CONTROL OF YOUR MOTORCYCLE}.

– A^FTERFALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

^{THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN}.

– D^{IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND}

^{BRAKE DISCS}.

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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.

– N^{EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS}

^RUNNING.

– M^{OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING}. THE

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

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

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

NOT LIKELY TO TOUCH IT AND GET BURNED

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

^{TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS}.

– N^{EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS}

^RUNNING.

CAUTION

– C^{LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE}.OTHERWISE THE CARBURETOR

^{CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE}.

– A^{LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT}

^{IT CANNOT BE USED BY UNAUTHORIZED PERSONS}.

INFORMATION ABOUT THE SIDE STAND:

Use your foot to push the side stand forward as far as possible, and lean

your motorcycle to the side. Make sure that your motorcycle is standing

safely on solid ground. Just in case, you can also put in a gear.

CAUTION

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

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

^STAND, ^{YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME}, AND YOUR

^{MOTORBIKE MAY FALL OVER}.

NOTE REGARDING THE CENTER STAND: (is available as an accessory)

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

stand as effortlessly as possible:

a) press main stand to ground using foot

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

illustrated (see illustration).

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

securely.

CAUTION

T^{HE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY}. BY

^{SITTING ON THE MOTORCYCLE}, YOU WILL PUT ADDITIONAL WEIGHT ON THE CENTER

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

^{MOTORCYCLE TO FALL DOWN}.

Fuel

In the condition at delivery, the LC4 engine requires unleaded premium-

grade fuel with at least 95 octane (ROZ).

If using lower octane fuel, it is easy to change over to the pre-programmed

ignition curve for 80 - 94 octane (ROZ) (see activating the ignition curve for

low-octane fuel).

CAUTION

USE UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE

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

^OCCUR.

WARNING

35 mm

G^{ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS}. EXTREME CAUTION SHOULD BE USED

^{WHEN HANDLING GASOLINE}. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR

BURNING ^CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE

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

^HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES,

^{SEEK A DOCTOR}’S ADVICE IMMEDIATELY.

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

the top (see fig.).

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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

Check the oil level in the master cylinder of the hydraulic clutch

Clean air filter and air filter box

Check cables for damage and kink-less arrangement

Check headlamp adjustment

Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,

tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)

Make sure all screws and nuts are tight.

Check brake fluid level, lining thickness, and brake discs

Check brake lines for damage and leaks

●

Check/adjust smooth operation, free travel of handbrake/footbrake levers

Check screws of brake system for tight fit

Check suspension strut and fork for leaks and proper operation

Check O-ring of suspension strut for wear

Clean fork dust sleeves

Bleed fork legs

Check swinging-fork pivot

Check/adjust steering-head bearing

Lubricate reversing lever

Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,

swinging-fork pivot, reversing lever, suspension strut)

Check spoke tension and rim joint

●

Check tire condition and inflation pressure

Check chain and chain guides for wear, force fit and tension.

Check screws on pinion and chain sprocket for locking devices and a tight fit.

Lubricate chain

Check wheel bearings and jerk damper for play

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

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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640 LC4

640 LC4 SUPERMOTO

PERIODIC MAINTENANCE SCHEDULE

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 (depending on the dirt accumulation)

Check tire pressure and wear

●

Check coolant level

Check fuel lines for leaks

Drain float chamber

●

Check all control elements for smooth running.

Check brake performance

●

Treat exposed metal components (except for the braking and exhaust

systems) with wax-based anti-corrosion agents

Treat ignition/steering lock and light switch with contact spray

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

●

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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. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A

SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY

QUALIFIED,SKILLED STAFF.

CAUTION

– W^{HEN CLEANING THE MOTORCYCLE}, ^{DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE}, OTHERWISE WATER WILL PENETRATE THE BEARINGS,

CARBURETOR, ELECTRIC CONNECTORS ETC.

– W^{HEN TRANSPORTING YOUR}KTM, ^{ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES}. IF THE

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

– D^{O NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS}, AS THESE WORK INTO THE FRAME PARTS AND KEEP

^{WORKING LOOSE}. INSTEAD, ^{USE SELF}-LOCKING NUTS.

– L^{ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED}.

– D^{ISPOSE OF OIL}, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS.

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

1,000.000 LITERS WATER.

–

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

– A^{FTER REMOVING ANY SCREWS AND NUTS SECURED WITH}LOCTITE THEY MUST BE MOUNTED AND SECURED IN THE SAME MANNER (SEE TECHNICAL

DATA – T^IGHTENINGT^ORQUES).

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 4 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

20 Nm.

WARNING

I^{F THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY}, THE MOTOR-

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

^CONTROL.

CAUTION

I^{F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS}, FIRST

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

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

Bleeder screws for telescopic fork

After every 5 hours of use for competitive racing, slacken the breather

plugs 3 a few turns in order to relieve excess pressure from the inside of

the fork. To do this, place the motorcycle on a stand with the front wheel

lifted off the ground. When riding the motorcycle mainly on street, it will be

enough to have this job performed in the course of the periodical

maintenance service.

CAUTION

E^{XCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK}. I^F

^{YOUR FORK IS LEAKING}, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE

^{HAVING THE SEALS REPLACED}.

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows 4 are to remove dust and coarse dirt particles

from the fork tube. However, after some time, dirt may also get in behind

the dust-protection bellows. If this dirt is not removed, the oil sealing rings

located behind it may start to leak.

Use a screwdriver to lever the dust-protection bellows out of the outer

tubes and slide them downward.

Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and

oil them thoroughly with silicone spray. Then, push dust-protection bellows

into the outer tubes by hand.

WARNING

NO SILICONE OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD

^{CONSIDERABLY REDUCE THE TIRE}'S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT

^BRAKE.

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Changing the spring preload of the shock absorber

KTM sets the shock absorber for a driver only, weighing approximately 75

kg (165 lb). If you want to take a passenger with you, of if you weigh

considerably more or less than 75 kg (165 lb), you should change the spring

preload accordingly A. This is easily done.

NOTE:

– Before changing the spring preload note down the basic setting, e.g.

how many threads are visible above the adjusting ring.

– One rotation of the adjusting ring 2 changes the spring preload by

approximately 1.75 mm (0.07 in).

Loosen the locking ring 1with the hook wrench from the tool set. Change

the spring preload with the adjusting ring 2and retighten the locking ring.

BASIC SETTING – SPRING PRELOAD:

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

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

Lubricating the shock absorber linkage

The bearings in the rocker arm must be greased (Motorex Long Therm

2000) in regular intervals. For this purpose, a grease nipple 3 is mounted

on the rocker arm.

CAUTION

A^{FTER EACH TIME THE MOTORCYCLE IS WASHED}, ^{IT IS ESPECIALLY IMPORTANT TO}

GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.

Checking rubber ring on the WP rear shock absorber

A rubber ring mounted on the rear shock absorber serves as a vibration

damper. This ring gets pressed together with time and loses its shock

absorbing quality.

Measure the distance between the two discs at various points around their

circumferences. The space should be at least 2.5 mm (0.1 in) wide. Have

the rubber ring replaced by an KTM dealer when compaction due to wear

has exceeded this lower limit.

CAUTION

N^{OT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK}

^ABSORBER.

min. 2,5 mm

WARNING

T^HEDAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED

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

^{MAINTENANCE WORK YOURSELF}. S^{EVERE INJURIES COULD BE THE RESULT}.

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Checking chain tension

To check, jack up the motorcycle on the center stand or frame until it no

longer touches the ground.

Press the chain up approx. 30 mm behind the end of the chain sliding

component. The chain should barely touch the swing arm when the upper

chain part Ais tensioned. If not, correct the chain tension.

WARNING

– I^{F CHAIN TENSION IS TOO GREAT}, PARTS WITHIN THE SECONDARY POWER TRANS-

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

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

^{EVEN CHAIN BREAKAGE}.

– T^{OO MUCH SLACK IN THE CHAIN}, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

^{JUMPING OFF THE CHAIN WHEELS}. I^{F THIS HAPPENS}, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

–

Correct chain tension

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

adjusting screws 3equally far. Tighten counter nuts 2.

Before tightening the wheel spindle, verify that the chain adjusters 4 are

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

aligned with the front wheel.

Tighten collar nut 1with 80 Nm.

WARNING

I^{F YOU DON}’^{T HAPPEN TO HAVE A TORQUE WRENCH AT HAND}, ^{MAKE SURE YOU HAVE}

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

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

NOTE: The large adjusting range of the chain adjusters 32mm (1.28 in)

allows you to use different secondary ratios in combination with the same

chain length. The chain adjusters 4can be rotated by 180°.

CAUTION

ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

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Chain maintenance

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

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

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

special X-ring chain spray (Motorex Chainlube Racing).

WARNING

N^{O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK}, EITHERWISE

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

^{REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL}.

CAUTION

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

POINT IN RUNNING DIRECTION.

●

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

Chain wear

In order to check the chain wear, regard the following instructions:

Shift the gear into idling and pull the upper chain strand with approx. 10-15

kilogramm (33 lb) upwards (see figure). Now one can measure a space of

18 chain reels at the lower chain strand. The chain should be replaced at the

latest when a space of 272 mm (10.88 in) is measured. Chains do not

always wear off evenly, therefore repeat the measurement at different

places on the chain.

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.

max. 272 mm

16 17 18

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General informations about KTM disc brakes

BRAKE CALIPERS (LC4):

LC4

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

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

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

caliper support with Loctite 243 and tighten to 25 Nm.

BRAKE CALIPERS (LC4 SUPERMOTO):

The front brake caliper 1 has 4 brake pistons and is rigidly connected to

the fork leg. The rear brake caliper has one brake piston and "floats", which

means that it is not rigidly connected to the brake caliper support. The

resulting lateral adjustment ensures that the brake pads 2 optimally rest

against the brake disk at any time. Secure the screws 3 of the caliper

support with Loctite 243 and tighten to 40 Nm.

LC4 SUPERMOTO

BRAKE PADS:

The motorcycles are delivered with organic brake pads and have also been

type-coded with these pads. Said pads are suitable for almost the entire

range of application of these motorcycles.It is only for competitive racing in

extremely dirty conditions (e.g., water in combination with sand and mud)

that we recommend brake pads that have sintered linings. However, take

notice of the fact that brake pads with sintered linings have not been type

coded! Besides, they may cause greater wear on the brake discs.

WARNING

B^{RAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZED FOR}

^{OPERATION OF YOUR}KTM ^{MOTORCYCLE IN ROAD TRAFFIC}. THE BRAKE PADS DESIGN

AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN DEVIATE

SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFERENT BRAKE PADS

^{THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT}, IT CANNOT BE WARRANTED

^{THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC}. Y^{OUR MOTORCYCLE WILL NOT}

LONGER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR

^{ROAD TRAFFIC AND THE WARRANTY WILL BE VOID}.

BRAKE FLUID:

KTM fills the brake systems with „Motorex Brake Fluid DOT 5.1“ brake

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

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

and of an amber color. If you do not have any DOT 5.1 for refilling, you

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

possible by DOT 5.1.

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

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

WARNING

HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR

^{MOTORCYCLE OFTEN}, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.

B^{RAKE FLUID TENDS TO ABSORB WATER}. T^HEREFORE, VAPOR POCKETS MAY FORM IN

"OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO

^FAIL.

DOT

5.1

DOT

BRAKE FLUID RESERVOIRS:

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

designed in such a way that even if the brake pads are worn it is not

necessary to top up the brake fluid. If the brake fluid level drops below the

minimum either the brake system has a leak or the brake pads are

completely worn down. In this case, consult an authorized KTM dealer

immediately.

●

BRAKE DISCS:

Wear reduces the thickness of the brake disc in the area of contact 4with

the brake pads. At its thinnest spot A, the brake disc must not be more

than 0.4mm thinner than its nominal dimension B. The nominal dimension

can be gaged in a location beyond the area of contact with the brake pads.

Check wear in several spots.

WARNING

– B^{RAKE DISCS SUFFERING FROM WEAR GREATER THAN}0.4 MM CONSTITUTE A SAFETY

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

^{WEAR LIMIT}.

– A^{S A MATTER OF PRINCIPLE}, HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT

^{BY A LICENSED}KTM MECHANIC.

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

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

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

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

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

you press the hand brake lever forwards, you should have at least 3 mm

(0.12 in) free travel. Turn the adjusting screw 1if necessary.

CAUTION

min. 3 mm

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

^{THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED}(TO BE RECOGNIZED BY

THE ^{GREATER RESISTANCE OF THE HAND BRAKE LEVER}). IF THIS FREE TRAVEL IS NOT

^PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT WHEEL

^{BRAKE MAY FAIL DUE TO OVERHEATING}.

Changing the basic position of the handbrake lever (LC4

Supermoto)

The adjusting screw 2allows you to change the basic position of the hand-

brake lever 3.

Press the handbrake lever's outer end forward, and, at the same time, turn

the adjusting screw.

Checking of brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the

handlebar and the reservoir is provided with an inspection glass. With the

reservoir in a horizontal position, the brake fluid level should not go below

middle of the glass.

WARNING

I^{F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A}

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

^AUTHORIZEDKTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws 4and remove lid 5and membrane 6.

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

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

reservoir to 5 mm (0.2 in) below the rim with brake fluid DOT 5.1 (Motorex

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

spilled or overflowing brake fluid with water.

WARNING

– N^{EVER USE}DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

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

– S^{TORE BRAKE FLUID OUT OF REACH OF CHILDREN}.

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

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

^{A DOCTOR}.

CAUTION

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

^REMOVER.

– U^{SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER}.

5 mm

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Checking the front brake pads (LC4)

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

1 mm (0.04 in) thick.

min.

1 mm

WARNING

A^{T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN}

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

^DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

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

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

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

Checking the front brake pads (LC4 Supermoto)

min.

1 mm

The brake pads can be inspected from behind. Always inspect the brake pad

linings before taking off on your motorcycle. They should not be thinner

than 1 mm (0.04 in) which is the case when the notch A is no longer

discernable.

WARNING

A^{T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN}1

MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T

^{PUT OFF HAVING YOUR BRAKE PADS CHANGED}.

VORSICHT

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

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

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

Changing the basic position of the foot brake pedal *

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

roller 1. The free play at the foot brake pedal must then be adjusted by

means of the piston rod 2.

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

(0.12–0.20 in) of free play, before the piston rod can move the piston in the

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

brake pedal).

NOTE: To prevent the stop roller from turning when tightening, counteract

by inserting a hexagon socket wrench in hole Bprovided for this purpose.

CAUTION

3-5mm

I^{F 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}.

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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

I^{F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A}

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

^AUTHORIZEDKTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

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

the brake fluid reservoir.

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

the hexagon screw 1. Then move the container outwards as indicated in

the illustration. Remove plug 2 with rubber boot 3 and add brake fluid

DOT 5.1 (Motorex Brake Fluid DOT 5.1) up to the „MAX“ mark. Replace

rubber boot and plug. Overflown or spilled brake liquid must be rinsed off

with water. Mount the screw and fix the brake fluid reservoir to the frame,

always making sure to prevent kinks in the connecting hose.

WARNING

– N^{EVER USE}DOT 5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

^COLOR. S^{EALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT}.

– S^{TORE BRAKE FLUID OUT OF REACH OF CHILDREN}.

– B^{RAKE FLUID CAN CAUSE SKIN IRRITATION}. AVOID CONTACT WITH SKIN AND EYES. IF

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

A DOCTOR

CAUTION

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

REMOVER.

– U^{SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER}.

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 (0.04 IN), OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN

^{SAFETY DON}’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

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

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

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

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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

moderately with a 6 mm (0.24 in) ALLAN/IMBUS key while pulling.

Carefully remove the front wheel from the fork.

CAUTION

– DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN

^DISMOUNTED.

– A^{LWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING}

UPWARDS. O^{THERWISE THE BRAKE DISC MAY BE DAMAGED}.

To install the front wheel, lift it into the fork, position and mount the axle

shaft. Mount the collar nut 1, tighten the clamping screws 2 on the right

fork leg axle passage to prevent the axle shaft from turning and tighten the

collar nut to 40 Nm.

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

from its stand. Press the front wheel brakes and push down on the fork a

few times vigorously so that the fork legs come into alignment.

Only after this has been accomplished, tighten the clamp screws on both

fork legs with 10 Nm.

WARNING

– I^{F YOU DON}’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY ^AKTM DEALER AS SOON AS

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

MOTORCYCLE.

– A^{FTER MOUNTING THE FRONT WHEEL}, KEEP OPERATING THE HAND BRAKE UNTIL THE

^{PRESSURE POINT RETURNS}.

– I^{T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS},

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

Dismounting and mounting the front wheel (LC4 Supermoto)

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

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

to be removed. To remove the front brake caliper, remove both screws 4

and pull the caliper backwards from the brake disc.

After mounting the front wheel, slide the brake caliper to the brake disc.

Remove the grease from the threads of both screws 4 and apply Loctite

243. Tighten the screws with 40 Nm.

WARNING

THE SCREWS 4MUST BE SECURED WITH LOCTITE 243.

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Dismounting and mounting the rear wheel

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

rear wheel no longer touches the ground.

Loosen the collar nut 1, remove chain tensioner 2, hold the rear wheel

and pull out the wheel spindle 3 until the rear wheel is free but the brake

caliper support is still held. Push the rear wheel as far forward as possible,

take the chain from the rear sprocket and carefully take the rear wheel out

of the swingarm.

CAUTION

– D^{O NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED}.

– A^{LWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING}

^UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

– I^{F THE AXLE IS DISMOUNTED}, CLEAN THE THREAD OF THE WHEEL SPINDLE AND

^{COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE}(MOTOREX LONG

THERM 2000) ^{TO PREVENT THE THREAD FROM JAMMING}.

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

shock absorption rubber.

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

nut to 80 Nm, push the rear wheel forwards so that the chain

tensioners lie on the tension screws.

WARNING

– I^{F YOU DON}’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY ^AKTM DEALER AS SOON AS

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

^{OF YOUR MOTORCYCLE}.

– A^{FTER MOUNTING THE REAR WHEEL}, KEEP OPERATING THE FOOTBRAKE UNTIL THE

^{PRESSURE POINT RETURNS}.

– I^{T 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 4

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

I^{N ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE}, ONLY KTM-

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

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

Approved tires for 640 LC4 (as of July 2002)

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

METZELER . . . . . . . . . . . . . .E^NDURO3, ENDURO 4, KAROO

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

PIRELLI . . . . . . . . . . . . . . . .MT21, MT60, MT70, MT90

– Tire type and size can be found in the technical specifications and in the

homologation certificate

– Tire condition has to be checked every time you want to ride your

motorcycle. Before leaving check for punctures and nails or other sharp

objects that might have become embedded in the tire.

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

requirements. We recommend replacing tires at the latest when the

tread is down to 2 mm (0.08 in).

TIRES - AIR PRESSURE

front

rear

640 LC4

Road, driver only

1,8 bar (26psi) 2,0 bar (29psi)

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

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

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

640 LC4 Supermoto

front

rear

WARNING

Road, driver only

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

– D^{O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY}KTM. OTHER TIRES

^{COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES}.

– U^{SE TIRES OF THE SAME BRAND AND TYPE FOR THE FRONT AND REAR WHEELS}.

– F^{OR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY}.

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

– W^ORNTIRES CAN HAVE

NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

^PERFORMS, ^{ESPECIALLY ON WET SURFACES}.

– I^{F AIR PRESSURE IS TOO LOW}, ABNORMAL WEAR AND OVERHEATING OF THE TIRE

^{CAN RESULT}.

– N^{EW WHEELS HAVE A SMOOTH SURFACE}, WHICH MEANS THAT THEY MUST BE RUN IN

^{TO ACHIEVE FULL GRIP}. F^{OR THIS PURPOSE}, ^{RIDE THE MOTORCYCLE CAREFULLY AT}

^{MODERATE SPEED DURING THE FIRST}200 KILOMETERS WITH NEW TIRES, TILTING THE

^{VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED}.

T^IRESWILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE

^{PROPERLY RUN IN}.

– F^{OR REASONS OF SAFETY}, IT IS RECOMMENDED TO EXCHANGE THE VALVE INSERT

^{WHENEVER A NEW TIRE IS MOUNTED}.

Checking spoke tension

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

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

– S^{POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE}. THIS MAY LEAD TO

AN UNSTABLE HANDLING OF YOUR MOTORCYCLE.

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

^{SPOKES MUST BE TENSIONED TO}4 NM.

Changing the wheel size

10 sec

The preset wheel diameter (21, 19 or 17“) and the respective wheel circum-

ference (2205, 2040 or 1882 mm) are displayed briefly when the ignition is

switched on.

To change the wheel diameter, switch on the ignition, change to the ODO

mode and press the MODE and SET buttons simultaneously for approx. 10

seconds. The display will start to blink. Select the wheel diameter using the

MODE button, press the SET button to confirm and save the setting.

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Battery

The battery is located under the seat and is maintenance-free.

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

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

grease if necessary.

REMOVING THE BATTERY:

Remove screws

the way.

and swing retaining bracket and voltage regulator out of

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

Remove battery.

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

WARNING

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

^CARE. T^{HE ELECTROLYTE CAN CAUSE SEVERE BURNS}.

– I^{N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER}.

– I^{N THE CASE OF CONTACT WITH THE EYES}, THOROUGHLY RINSE EYES WITH WATER

^{FOR AT LEAST}15 ^MINUTES. I^{MMEDIATELY CONSULT A DOCTOR}.

– T^{HE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES}.

A^{VOID SPARKS AND OPEN FIRE NEAR THE BATTERY}.

– D^{EFECTIVE 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

– N^EVERDISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL

^{DESTROY THE RECTIFIER}-^REGULATOR.

– T^{HE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT}(AS

^{SHOWN IN THE ILLUSTRATION}), OTHERWISE ELECTROLYTE CAN ESCAPE.

BATTERY STORAGE:

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

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

expose to direct sunlight.

Charging the battery

NOTE: A battery charger, item no. 58429074000 is available from your

KTM dealer.

You can also use the battery charger to test the battery's off load voltage,

startability and the generator capacity.

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

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

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

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

Recharging is not required if the voltage exceeds 12.4 V.

Recharge if the voltage is below 12.4 V.

CHARGING:

Charge the battery for 5 to a max. of 10 hours with 0.9 amperes and a

max. of 14.4 volts.

For a quick charge, do not charge the battery longer than 1 hour with 4.5

amperes and a max. of 14.4 volts.

CAUTION

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

^CHARGED5 TO A MAX. OF 10 HOURS WITH 0.9 AMPERES AND A MAX. OF 14.4

VOLTS.

– A^{LWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE}

^{CHARGING UNIT ON}.

– W^HENRECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT

^VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING

^PROCESS.

VOLT

– C^{HARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES}.

O^{THERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES}.

– A^{VOID QUICK CHARGING IF POSSIBLE}.

– T^{O AVOID DAMAGE}, DO NOT REMOVE THE LOCKING BAR.

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Fuses

Fuse box Ais located under the seat.

See "Removing the seat" to remove and mount the seat.

The fuses are numbered on the inside of the fuse box.

The fuses marked "RES" are spare fuses.

Main fuse 1 (20 amperes) protects all power consumers against short

circuits.

Fuse 2 (10 Ampere) protects the following power-consuming units:

– electronic speedometer

– capacitor

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

– ignition

– starter system

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

– flasher lights

– brake light

– horn

Fuse 5 (10 Ampere) protects the following power-consuming units:

– headlight

– parking light

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

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

inspected by a KTM dealer.

CAUTION

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

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

^{ELECTRICAL INSTALLATION}!

Exchanging the headlight lamp

Replacing the headlight bulb

Remove the headlight mask:

Remove screw

on the left and right.

Tilt the headlight mask to the front and detach from the lower fender.

Exchanging the headlight lamp:

Disconnect plug

from the bulb.

Remove the rubber cap

Unhook the retaining bracket, then remove the bulb.

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

is located in the corresponding groove in the socket.

CAUTION

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

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

^{GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR}.

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

to the bulb.

Mount the headlight mask:

Position the headlight mask such that the headlight is located under the

cockpit.

Fit the headlight mask into the fender and mount screws

Replacing the parking-light bulb

Disassemble the headlight as described above and simply pull the bulb

socket 5out 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.

NOTE: Since the bulb on the tail end is subjected to higher vibrations,

heavy-duty bulbs are available from your KTM dealer.

Cooling system

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

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

cylinder head. After the engine has reached its operating temperature

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

pumped through both aluminum radiators.

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

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

radiator fins also reduce the cooling efficiency.

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

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

rise. If the coolant temperature rises to 85°C (184°F), the fan 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 TEMPERATURE WARNING LAMP FOR THE COOLING LIQUID 4 WILL BEGIN TO

^{BLINK WHEN THE COOLING LIQUID HAS REACHED APPROX}. 120°C (246°F), EXCEEDING

^{THE NORMAL OPERATING TEMPERATURE}.

P^{OSSIBLE CAUSES}:

– S^{LOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE}:

I^FPOSSIBLE INCREASE YOUR RUNNING SPEED, SO THAT MORE AIR CAN BLOW

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

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

^{POSSIBLE CAUSES}.

– T^{OO LITTLE COOLING LIQUID IN THE SYSTEM}:

L^{ET THE ENGINE COOL DOWN}, AND CHECK THE SYSTEM FOR LEAKAGE’S. ALSO

^{EXAMINE THE COOLING LIQUID LEVEL}CAUTION SCALDING HAZARD! DO NOT

^{DRIVE ON}, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. GO TO YOUR

^NEARESTKTM 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:

T^{HE COOLING FAN MUST BE RUNNING}, WHEN THE COOLING LIQUID TEMPERATURE IS

100°C (210°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORKING, AND THERE

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

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

–

CONTINUOUS USE OF THE CLUTCH (RIDING THE CLUTCH) AT LOWER SPEEDS.

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

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

from antifreezing protection, this mixture also provides great corrosion

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

CAUTION

F^{OR THE COOLING SYSTEM}, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTI-

F^REEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND

^{COOLANT FOAMING}.

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

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

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

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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

– I^{F POSSIBLE}, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF

^{YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT}, USE A RAG TO

^{COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE}. CAUTION - SCALDING

HAZARD !

– D^{O NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT}. THE ESCAPING

^{HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS}.

– I^{N CASE YOU GET BURNT}, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

^{COLD WATER RIGHT AWAY}!

– C^{OOLANT IS TOXIC}. K^{EEP THE COOLANT OUT OF THE REACH OF CHILDREN}!

– I^{N CASE COOLANT IS INGESTED}, GO SEE A DOCTOR IMMEDIATELY!

– I^{F COOLANT GETS INTO YOUR EYES}, RINSE THEM OUT WITH WATER IMMEDIATELY

AND GO SEE A DOCTOR!

Cleaning the air filter *

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

regularly.

To clean the air filter, remove screws 1 and the filter box cover. Detach

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

from the filter box.

Remove the air filter from the filter holder and wash thoroughly in special

cleaning fluid. Motorex offers environmentally-friendly products for

professional oil filter maintenance (Motorex Bio Dirt Remover + Motorex

Liquid Bio Power). Press out the water from the air filter but do not wring

and allow the filter to dry. Lubricate the dry air filter thoroughly with

highgrade filter oil, rubbing to coat the entire filter surface.

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

damage.

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

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

positioned correctly and mount the filter box cover.

CAUTION

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

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

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

– N^{EVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS}. OTHERWISE, DUST

^{AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR}.

– D^{UST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS}

^{NOT MOUNTED CORRECTLY}.

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Changing the original position of the clutch lever

The adjusting screw 1can be used for individual adjustment of the original

position of the clutch lever, thus allowing adjustment to an optimal position

for every hand size.

Turning the adjusting screw clockwise reduces the distance between the

clutch lever and the handlebar. Turning the adjusting screw counterclock-

wise increases the distance between the clutch lever and the handlebar.

CAUTION

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

O^{NLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE}.

Checking the oil level of the hydraulic clutch *

To check the oil level in the master cylinder of the clutch remove the

cover. For this purpose, remove screws 2 and cover 3 together with

the rubber boot 4. The oil level in the horizontal-standing master

cylinder should be 4 mm (0.16 in) below the upper edge.

If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungs-

fluid 75), available from your authorized KTM workshop.

CAUTION

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL.

N^{EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS}.

A^LWAYSUSE BIODEGRADABLE HYDRAULIC ^OILSAE 10 TO FILL UP THE MASTER

^CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

Adjust the throttle cable *

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

3-5 mm (0.12-0.2 in).

3-5 mm

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

protection cover 5. To set the backlash, loosen the counter nut 6and turn

the adjusting screw 7 accordingly. Then, fasten the counter nut and slide

the protection cover back on.

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

once you let go of it.

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

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

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

the throttle cable.

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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).

CAUTION

4 mm

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

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

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

Remove the seat and tank to adjust.

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

I^{F THERE IS NO PLAY IN THE DECOMPRESSION LEVER}, THIS CAN RESULT IN ENGINE

^DAMAGE.

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

Activating the ignition curve for low-octane fuel

If you are traveling to a country where fuel having at least 95 octane (ROZ)

is not available, you can easily activate the corresponding ignition curve.

A socket connector 6 is located on a brown-black cable near the digital

box.

If the two connectors are connected to each other, the ignition curve for

fuel having at least 95 octane (ROZ) is activated.

If you disconnect the plug and socket connection, the ignition curve for fuel

having 80 - 94 octane (ROZ) is activated. Although this causes the engine

to lose some of its power output, it prevents poor glow ignitions and engine

damage.

CAUTION

IF FUEL HAVING AT LEAST 95 OCTANE (ROZ) IS NOT AVAILABLE, THE IGNITION CURVE

^FOR80 - 94 OCTANE (ROZ) MUST BE ACTIVATED TO PREVENT ENGINE DAMAGE.

Adjust idling speed *

Use the adjusting screw

to adjust the basic position of the throttle valve

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

idling speed, turning in counterclockwise direction will reduce the idling

speed. Normal idling speed 1400 - 1500 rpm.

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Draining the carburetor float chamber *

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

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

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

Carry out this job with the engine being cold.

Close the fuel tap.

Put one end of the hose 1 that leads downward behind the engine into a

collecting vessel.

Open the drain plug 2 (turning it counterclockwise) by several turns, and

drain the fuel from the float chamber.

Then, retighten the drain plug and open the fuel tap.

WARNING

F^{UEL IS HIGHLY FLAMMABLE AND TOXIC}. BE EXTREMELY CAUTIOUS WHEN HANDLING

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

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

^{FUEL IMMEDIATELY}. M^{ATERIALS SATURATED WITH FUEL ARE HIGHLY FLAMMABLE}, AS

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

^EYES, GO SEE A PHYSICIAN IMMEDIATELY.

Engine oil

Automobile engine oil used to be used for four-stroke motorcycles before

there were separate motorcycle specifications. Different technical develop-

ments made it necessary to have a separate specification for four-stroke

motorcycles - the JASO T903 MA standard. Whereas car engines require

long changing intervals, motorcycle engines require a higher power output

at higher speeds. Most motorcycle engines also use the same oil to lubricate

the transmission and the clutch. The JASO MA standard responds to these

special requirements.

JASO T903 MA

TEMPERATUR

0°C

32°F

Only use fully synthetic engine oils that meet the JASO MA quality require-

ments (see information on the can).

KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for

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

32°F).

5W/40

10W/50

Checking the engine oil level

The engine oil level can be checked when the engine is cold or warm.

To check, place the motorcycle in an upright position on a level surface

(center stand).

If the engine is cold, the oil level should be visible at the lower edge A of

the inspection glass.

If the engine is warm, the oil level should be visible at the upper edge Bof

the inspection glass.

Add engine oil if necessary.

CAUTION

– INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE WEAR

IN THE ENGINE.

– DO NOT OVERFILL THE ENGINE CASE.

– D^{O NOT UNDERFILL THE ENGINE CASE}.

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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

A^{N ENGINE HAVING BEEN RUN WARM}, AND THE ENGINE OIL IN IT IS VERY HOT - DO NOT

^{BURN YOURSELF}.

Place the motorcycle on a horizontal surface

Remove the two plugs

and

, and drain oil into a container.

CAUTION

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

Remove the screws and the cover bp. Loosen the fine screen filter 6 with

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

The screw bq must be removed to allow the motor oil to flow out of the

frame breast pipe.

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

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

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

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

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

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

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

Remove oil dipstick on the clutch cover, fill with 1.3 litre (0.34 US gallons)

engine oil and attach plug again.

CAUTION

– USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. USING ANOTHER FILTER BRAND CAN

^{RESULT IN DAMAGE TO THE ENGINE}.

– IF 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 (0.28 in) -diameter hole into the lid. Screw the hose

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

with the M8 hexagon nut.

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

filling tool.

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

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

hole A, (see page 30) and fill 0.6 liters (0.16 US gallons) of engine oil into

the frame’s front tube. Remove plastic hose, start engine, and let it idle

(approx. 20 seconds) until oil escapes at the hole A. As soon as oil begins

to leak out, switch off the engine, mount the plug and gasket and tighten

to 25 Nm.

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

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

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

wait for 5 minutes.Checking the oil level, he should be between the two

marks on the inspection glass, however, it must never rise above the MAX

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

engine venting system. Add engine oil, if necessary.

CAUTION

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

^ENGINE.

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

^{READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL}.

– D^{O NOT OVERFILL THE ENGINE CASE}.

– D^{O NOT UNDERFILL THE ENGINE CASE}.

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

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

breast pipe.

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

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

(0.264 US gallons) oil contaminates 1.000.000 liter (264.000 US gallons)

water.

Changing oil filter *

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

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

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

2and the three screws. Remove oil filter cover 3 and oil filter. Clean the

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

filter cover is not clogged.

Place the new oil filter 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. Tighten the hollow screw with seals and tighten to 15 Nm.

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 (3).

doesn't light up.

Blown main fuse.

Remove seat and replace the main fuse(1). 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. 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 (0.036 in)

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

(157°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)

Blown fuse

Use thicker engine oil; see chapter „Engine oil“

Replace fuse (5).

Headlight and parking light

fail

Blown fuse

Replace fuse (4).

Flasher lights, brake light,

fan and horn fail

Defect neutral switch.

Loose connections, defect cable.

Connect cable to ground; neutral switch must be replaced if

indicator lamp lights up.

The NEUTRAL lamp is not

on even though the gear is

in NEUTRAL

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.

Main fuse melted through

Replace the main fuse (1) under the seat

No values are visible in the

Tripmaster display.

Defective sensor cable or oxidized Check the sensor cable for damage and replace it if necessary.

No speed display.

socket connector.

Remove the headlight mask and check the socket connector.

Contact 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

^{DESTRUCTION OF THESE PARTS}.

PREMATURE

– 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

K^{EEP ANTI}-^{CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS}, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING

^POWER.

CAUTION

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 2004

640 LC4

640 LC4 Supermoto

Frame

Central chrome-moly-steel frame

Fork

White Power – Up Side Down 4357 MXMA

White Power – Up Side Down 4860 MXMA

Wheel travel front/rear

Rear suspension

Front brake

275 / 290 mm (11 / 11.6 in)

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

265 / 300 mm (10.6 / 12 in)

Disc brake with carbon-steel brake disc,

2-piston brake caliper floated

Ø 300 mm (12 in)

Disc brake with carbon-steel brake disc,

4-piston brake caliper

Front brake disc

Rear brake

Ø 320 mm (12.8 in)

Disc brake with carbon-steel brake disc ꢀ 220 mm (8.8 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)

130/80-18

Air press. road, driver only

Air press. road with passenger

Fuel tank capacity

Final drive ratio

Chain

2.0 bar (29 psi)

2.2 bar (31 psi)

2.4 bar (34 psi)

12 liter (3.1 US gallons), 2.5 liter (0.6 US gallons) reserve

16:42t 17:42t

X – Ring 5/8 x 1/4"

Bulps

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

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

instrument lights . . . . . . . . LED

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

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

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

license plate illmination . . . 12V 5W (socket W2,1x9,5 d)

maintenance-free battery 12V 8,6Ah

Battery

Steering angle

62°

63°

Wheel base

1510 10 mm (59.4 0.4 in)

Seat high

925 mm (36.4 in)

310 mm (12.2 in)

149kg (329 lbs)

910 mm (35.9 in)

290 mm (11.4 in)

149 kg (329 Ibs)

Ground clearance

Dead weight without fuel

Max. permissible front axle load

Max. permissible rear axle load

Max. permissible laden weight

150 kg (331 lbs)

200 kg (441 lbs)

350 kg (773 lbs)

STANDARD ADJUSTMENT - FORK

STANDARD-ADJUSTMENT - SHOCK ABSORBER

640 LC4

SUPERMOTO

WP 1418Y750

640 LC4

SUPERMOTO

WP 0118Y733

WP 0518Y737

WP 0118Y734

Compression adjuster

Rebound adjuster

Spring

Compression adjuster

Rebound adjuster

Spring

4,2 N/mm

5 mm (0.2 in)

4,4 N/mm

28 mm (1.1 in)

66/260

70/260

Spring preload

Air chamber length

Fork oil

Spring preload

23,5 mm(0.93 in)

16 mm(0.63 in)

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

SAE 5 SAE 5

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TIGHTENING TORQUES - CHASSIS

Collar nut front axle

Collar nut rear axle

Shock absorber top

Shock absorber bottom

Collar screws brake disk front/rear

Screw brake caliper front (LC4)

Screw brake caliper front (Supermoto)

Bearing bolt linkage arm/frame

Collar nuts rocker arm bolts

Engine mounting screw

M16x1.5

M20x1.5

M10

M6 (10.9)

M10

M12

M14x1.5

M10

40 Nm

80 Nm

45 Nm

Loctite 243 + 10 Nm

Loctite 243 + 25 Nm

Loctite 243 + 40 Nm

60 Nm

100 Nm

45 Nm

Loctite 243 + 25 Nm

Loctite 243 + 35 Nm

100 Nm

Ball joint for push rod

Sprocket screws on nuts

M14x1.5

Hexagon nut swingarm bolt

Clamping screws top triple clamp

Clamping screws bottom triple clamp

Clamping screws fork stubs

Screws handlebar clamp

Allan head screw handle bar support

Bleeder screw oil reservoir frame

Spoke nipple

20 Nm

15 Nm

10 Nm

Loctite 243 + 20 Nm

25 Nm

M10

M16x1.5

4 Nm

Other screws on chassis

10 Nm

25 Nm

M10

45 Nm

15 Nm

Other collar nuts on chassis

30 Nm

M10

50 Nm

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TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2004

Engine

Design

640 LC4

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

Displacement

Bore / Stroke

Ratio

625 ccm

101 / 78 mm

11.7 : 1

Fuel

unleaded premium gasoline with at least RON 95

(USA = Premium RON 91) (RON 80-94 for other ignition curve

Valve timing

Camshaft

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

249/1

Valve diameter

Valve clearence cold

Crank shaft bearing

Connecting rod bearing

Top end bearing

Piston

Intake: 36 mm

Exhaust: 32 mm

0,15 mm Exhaust: 0,15 mm

2 cylinder roller bearing

needle bearing

bronze bushing

forged aluminium alloy

Piston rings

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

two Eaton-oilpumps

Engine lubrication

Engine oil

see bellow #

Engine oil quantity

Primary ratio

Clutch

appr. 2,1 liters including frame

straight geared spur wheels 31 : 79 teeth

multi disc clutch in oil bath, hydraulically operated

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 4K5

adjustment to max. 38° BTDC at 6000 rpm

12V 200W

Spark plug

NGK DCPR 8 E

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

BASIC CARBURETOR SETTING

640 LC4

640 LC4 Supermoto

JASO T903 MA

Type

BST40-266

152,5

Main jet

TEMPERATURE

Needle jet

X-6 689

0°C

32°F

Idling jet

Jet needle

6G5

Needle clip pos. f. top

Mixt. adj. screw open

3. from top

2,25

5W/40

10W/50

Engine oil

Only use fully synthetic engine oils that meet the

JASO MA quality requirements (see information on

the can).

KTM recommends Motorex Power Synt 4T in the

10W/50 viscosity (for temperatures over 0°C, 32°F)

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

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HEAD WORD INDEX

Page

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

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

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

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

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

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

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

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

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

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

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

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

Changing the basic position of the handbrake lever............26

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

Changing the spring preload of the shock absorber ............22

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

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

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

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

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

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

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

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

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

Checking rubber ring on the rear shock absorber................22

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

Checking the adjustment of the hand decompression cable ..37

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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KTM Group Partner

KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

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