Page 2 - ENGLISH; IMPORTANT; Chassis number; CONSUMER INFORMATION FOR AUSTRALIA ONLY
ENGLISH 1 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ...
Page 3 - Introduction; Before you go for your first ride, be sure to read this manual; Chassis and Engine” of this manual.
ENGLISH 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees tobring you lots of fun and enjoyment, provided that you clean and maintain itappropriately. Before you go for your first ride,...
Page 4 - INDEX
ENGLISH 3 Page SERIAL NUMBER LOCATIONS .............................................4 Chassis number ................................................................4 Engine number, engine type .............................................4 OPERATION INSTRUMENTS ........................................
Page 5 - Hand decompression lever; SERIAL NUMBER LOCATIONS
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...
Page 6 - Choke lever; Hand brake lever; Speedometer, indicator lamps; Ignition lock with 4 switch positions; Ignition lock with 3 switch positions
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 ...
Page 7 - Combination switch; Filler cap
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 ...
Page 8 - Fuel tap; Shift lever; Foot brake pedal; OFF
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...
Page 9 - Compression damping of fork; Rebound damping of shock absorber; Holding bars
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...
Page 10 - Running in the LC4 models; Instructions for initial operation; DRIVING INSTRUCTIONS
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...
Page 11 - Starting when the engine is cold; Starting when the engine is warm or hot
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...
Page 12 - What to do when the engine is „flooded”; Starting off; Braking
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...
Page 13 - Stopping and parking
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 ...
Page 15 - PERIODIC MAINTENANCE SCHEDULE; A washed motorcycle can be checked more quickly which saves money!; ENGINE
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...
Page 17 - Tool set; MAINTENANCE WORK ON CHASSIS AND ENGINE
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...
Page 18 - Checking and adjusting steering head bearing *; Changing the spring preload of the shock absorber
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...
Page 19 - Checking rubber ring on the WP rear shock absorber; Checking chain tension; Correct chain tension; Chain maintenance
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...
Page 20 - Chain wear; Adjusting of free travel at the hand brake lever; DOT
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...
Page 21 - Checking of brake fluid level - front brake; Refilling the front brake fluid reservoir*; Checking the front brake pads; Changing the basic position of the foot brake pedal*
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...
Page 22 - Checking rear brake fluid level; Refilling the rear brake fluid reservoir*; Checking the rear brake pads
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...
Page 23 - Dismounting and mounting the front wheel (LC4); Dismounting and mounting the front wheel (LC4 Supermoto)
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...
Page 24 - Dismounting and mounting the rear wheel (LC4); Checking the shock absorption rubbers in the rear hub *
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...
Page 25 - T I R E S - A I R P R E S S U R E; Checking spoke tension
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 ...
Page 26 - Battery; Charging the battery; VOLT
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...
Page 27 - Main fuse; Fuses for individual power-consuming units; Exchanging the headlight lamp; Replacing the parking-light bulb; bk
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 ...
Page 28 - Exchanging the brake light and tail light bulb
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...
Page 29 - Checking the cooling liquid level; Cleaning the air filter *; Adjust idling speed *
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...
Page 30 - Adjusting the throttle cable *; Draining the carburetor float chamber *; Adjusting the clutch cable
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...
Page 31 - Checking and adjusting the choke cable play *; Engine oil; Checking engine oil level; MAX; TEMPERATUR
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...
Page 32 - Oil circuit
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...
Page 33 - Changing oil filter *
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...
Page 34 - TROUBLE SHOOTING
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...
Page 37 - RE-INITIATION AFTER TIME OF STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
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...
Page 38 - STANDARD ADJUSTMENT - FORK
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...
Page 39 - TIGHTENING TORQUES - CHASSIS LC4
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...
Page 41 - CONSUMER INFORMA; STOPPING DIST; Model KTM; Light Load
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...
Page 44 - HEAD WORD INDEX
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 .........................
