KTM 640LC4 - Manuals

ENGLISH 4 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 ofthe engine below the chain sprocket. Write this num...

ENGLISH 5 Choke lever If the choke lever 1 is pulled backwards, a bore will be opened in the carburetor through which the engine may draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. If the choke leveris pushed forward up to the stop, the bore will be closed ...

ENGLISH 6 Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch 2 returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button 3 ...

ENGLISH 7 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 tankempties down to the fuel reserve of approx. 2.5 liters. RES The r...

ENGLISH 8 4 Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. Itonly regulates the degree of damping during compression. Remove closingcap A . By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwi...

ENGLISH 9 – Adjust the hand brake lever and the foot brake pedal to the most comfortable positions for you. – Get used to handling the motorcycle on an empty car park, before starting on a longer drive. Also try to drive as slowlyas possible and in standing position, to improve your feelingfor the v...

ENGLISH 10 1 2 4 5 3 6 Starting when the engine is cold 1 Open the fuel tap 1 2 Switch on ignition (turn ignition key 2 into position ). 3 Switch on emergency OFF switch 3 . 4 Switch transmission to idle (green indicator lamp N 4 lights up). 5 Operate cold starting device (choke) 5 . 6 Do not accele...

ENGLISH 11 What to do when the engine is „flooded” The throttle must be fully opened when starting. If necessarychange spark-plug. Kickstart instructions Start as described above, then push the kickstarter hard ALLTHE WAY. WARNING – W HEN STARTING THE ENGINE , MAKE SURE THAT YOU ALWAYS WEAR STURDY M...

ENGLISH 12 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 anarea where the ground is firm, and lock the motorcycle. WARNING – ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL ...

ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE 1. Service after 1000 km 2. Service after5000 km, then every 5000 km or once a year IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM . M AINTENANCE WOR...

ENGLISH 16 WARNING ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGEAND SKILLS OF A PROFESSIONAL. IN THE INTEREST OF YOUR OWN SAFETY, HAVE THESE PROCEDURES CARRIEDOUT AT A KTM SERVICE STATION! AT KTM YOUR MOTORCYCLE WILL RECEIVE OPTIMAL SERVICING BYSPECIALLY T...

ENGLISH 17 Checking and adjusting steering head bearing * Check steering head bearing for play periodicaly. To check this putmotorcycle on a stand so that the front wheel is off the ground. Now try tomove the fork forward and backward. To adjust, loosen the five clamp screws 1 of the top triple clam...

ENGLISH 18 Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibrationdamper. This ring gets pressed together with time and loses its shock absorbing quality. Measure the distance between the two discs at various points around theircircum...

ENGLISH 19 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. 10-15kilogramm (33 lb) upwards (see figure). Now one can measure a space of18 chain reels at the lower chain strand. The chain should be r...

ENGLISH 20 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 thereservoir in a horizontal position, the brake fluid level should not go belowmiddle of the glass. W...

ENGLISH 21 Checking rear brake fluid level The reservoir for the rear disc brake is located on the left-hand side of thevehicle next to the carburetor carburetor connection boot. The brake fluidlevel may not drop below the „MlN” marking when the vehicle is in anupright position. WARNING I F THE BRAK...

ENGLISH 22 Dismounting and mounting the front wheel (LC4) To remove the front wheel, jack the motorcycle up on its frame so that thefront wheel no longer touches the ground.Loosen both clamp screws 2 on the left fork leg. Then loosen the collar nuts 1 before loosening the clamp screws 2 on the right...

ENGLISH 23 Dismounting and mounting the rear wheel (LC4) Park the motorcycle on the center stand. The rear wheel must not touch theground.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 suppo...

ENGLISH 24 640 LC4 front rear Road, driver only 1,8 bar (26psi) 2,0 bar (29psi) Road, with passenger 2,0 bar (29 psi) 2,2 bar (31psi) 640 LC4 Supermoto front rear Road, driver only 2,0 bar (29psi) 2,2 bar (31psi) Road, with passenger 2,2 bar (31psi) 2,4 bar (34psi) T I R E S - A I R P R E S S U R E ...

ENGLISH 25 Battery The battery is mounted under the seat (remove the seat, see page 16).The battery has a closed system and therefore requires no maintenance. It isnot necessary to check the electrolyte level or to refill water. Simply keepthe battery poles clean and slightly grease them with an aci...

ENGLISH 26 Main fuse Located near the battery under the seat, the main fuse 1 protects all power consumers.Replace a blown fuse only with an equivalent one. If a new fuse that hasjust been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer.The fuse capacity is 20 ...

ENGLISH 27 Exchanging the brake light and tail light bulb Remove the cap 1 on the underside of the license plate retainer. Turn the lamp socket 2 approximately 30° counterclockwise and pull it out of the tail light housing.Slightly depress the bulb, turn it approx. 30° counterclockwise and pull itou...

ENGLISH 28 Checking the cooling liquid level The cooling liquid should be 10 mm (0,4 in) above the cooling elementswhen the engine is cold (cf. diagram). In the event of the cooling liquidbeing drained, always fill the system before hand, then top off while theengine is running. WARNING I F POSSIBLE...

ENGLISH 29 Adjusting the throttle cable * When starting to turn the throttle grip, you should feel an initial backlash of3-5 mm. If a correction is necessary, start by removing the tank. Slide back theprotection cover 1 . To set the backlash, loosen the counter nut 2 and turn the adjusting screw 3 a...

ENGLISH 30 Checking and adjusting the choke cable play * The choke lever must always have a play of approx. 4 mm (0,16 in).Remove the seat and tank to adjust. 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 th...

ENGLISH 31 Oil circuit The oil pump 1 pumps the motor oil past the bypass valve 2 and through the oil filter 3 . Beyond the oil filter, one of the oil lines forks off to a jet 4 that injects motor oil to the piston pin bearing and the piston head. Thesecond oil line leads the main oil flow to the fr...

ENGLISH 32 To facilitate bleeding of the oil system, we have added a hose connectionpiece and a plastic hose to the set of tools. Take an empty oil can (1 liter)and drill a 7 mm-diameter hole into the lid. Screw the hose connectionpiece into the lid from the outside, and secure it from the inside wi...

ENGLISH 33 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an erroroccur 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 op...

ENGLISH 36 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 harddirt can be removed before with the help of a soft water jet. ! CAUTION ! N EV...

ENGLISH 37 TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork W hite P ower – U p S ide D own 4357 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) Rear suspension Central shock absorber (WP BAVP3612) with...

ENGLISH 38 TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 SUPERMOTO 2002 Collar nut front axle M16x1,5 40 Nm (30ft.lb) Collar nut rear axle M20x1,5 80 Nm (59ft.lb) Shock absorber top M10 45 Nm (33ft.lb) Shock absorber bottom M10 45 Nm (33ft.lb) Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 1...

ENGLISH 40 REPOR TING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in adition to notifying KTM Sportmotorcycle USA, Inc. If NHTSA receive...

ENGLISH 43 page Adjisting of free travel at the hand brake lever ....................19 Adjusting idling speed .........................................................28 Adjusting the choke cable ...................................................30 Adjusting the clutch cable .........................