Page 2 - ENGLISH; IMPORTANT; WARNING; Frame number; Tampering with noise control system prohibited; COMSUMER 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; At the time this manual was typeset,
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 sport motorcycle that guarantees to bringyou lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride,...
Page 4 - IMPORTANT LIMITED WARRANTY AND
ENGLISH 3 In accordance with the international quality managementISO 9001 standard, KTM uses quality assurance processesthat lead to the highest possible product quality. IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The 640 LC4 models are designed to withstand normal use on roads and...
Page 5 - INDEX
ENGLISH 4 Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number ................................................................5Engine number, engine type .............................................5 OPERATION INSTRUMENTS .........................................
Page 6 - Chassis number; Hand decompression lever; Hand brake lever; SERIAL NUMBER LOCATIONS
ENGLISH 5 Chassis number The chassis number is stamped on the right side of the steering head tube.Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side ofthe engine below the chain sprocket. Write this num...
Page 7 - Multi-functional digital speedometer; Display; TEST
ENGLISH 6 Multi-functional digital speedometer The universal instrument is divided into 3 parts.Use the MODE and SET 1 button to change the display and the basic set- tings in the display.Display 2 shows all of the information that may be of interest to you. 5 display modes can be selected with the ...
Page 8 - Setting options in the display; mph
ENGLISH 7 Setting options in the display KILOMETERS OR MILES.You can have the speed and distance shown in kilometers or miles in thedisplay. 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 theMODE 1 butt...
Page 9 - Cooling liquid temperature display; Indicator lamps
ENGLISH 8 Cooling liquid temperature display The temperature display 1 is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the coolingliquid has reached a temperature of approx. 50°C. Each additional barrepresents 10°C more. When the upper b...
Page 10 - Combination switch
ENGLISH 9 Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch 2 returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button 3 ...
Page 11 - Fuel tap; Shift lever; OFF
ENGLISH 10 Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tankempties down to the fuel reserve of approx. 2.5 liters. RES The ...
Page 12 - Compression damping of fork; Holding bars
ENGLISH 11 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 clockwis...
Page 13 - GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE; Instructions for initial operation
ENGLISH 12 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read these operating instructions carefully before your first ride. – Enter the chassis, engine...
Page 14 - Check the following before each start; DRIVING INSTRUCTIONS
ENGLISH 13 Check the following before each start When you start, the motorcycle must be in perfect mechanical condition.For safety reasons, you should make a habit of performing an overall checkof your motorcycle before each start. The following checks should be performed: 1 CHECK OIL LEVEL Insuffic...
Page 15 - Starting when the engine is cold; Starting when the engine is warm or hot
ENGLISH 14 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 accelerate; operat...
Page 16 - Kickstart instructions; Starting off; Braking
ENGLISH 15 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 MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY . Y OU MIGHT SLIDE OFF THE KICKSTARTER , OR THE ENGINE MAY CAUSE THE KICKSTAR...
Page 17 - Stopping and parking; Fuel; CAUTION
ENGLISH 16 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 19 - PERIODIC MAINTENANCE SCHEDULE; A washed motorcycle can be checked more quickly which saves money!; ENGINE
ENGLISH 18 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 21 - Tool set; MAINTENANCE WORK ON CHASSIS AND ENGINE
ENGLISH 20 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 22 - Checking and adjusting steering head bearing *; Breather plug front fork; Cleaning the dust sleeves of the telescopic fork
ENGLISH 21 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 23 - Changing the spring preload of the shock absorber; Checking rubber ring on the WP rear shock absorber
ENGLISH 22 Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only, weighing approximately 75kg (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 springpreload accordingly A...
Page 24 - Checking chain tension; Correct chain tension
ENGLISH 23 Checking chain tension Support the motorcycle on the center stand or side stand, respectively.Switch transmission to neutral.Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sliding component until the upper part of the chain is tensioned (see illustration)Now, the di...
Page 25 - Chain maintenance; Chain wear
ENGLISH 24 Chain maintenance For long chain life, good maintenance is very important. X-ring chainsrequire only modest maintenance. The best way is to use lots of water, butnever use brushes or solvents. After letting the chain dry, you can use aspecial X-ring chain spray (Shell Advance Bio Chain). ...
Page 26 - General informations about KTM disc brakes; DOT
ENGLISH 25 General informations about KTM disc brakes BRAKE CALIPERS:The brake calipers of this series “float“. This means that the brake calipersare not solidly attached to the caliper support. Thus, the brake pads arealways in optimum contact with the brake disc. Secure the screws of thecaliper su...
Page 27 - Adjusting of free travel at the hand brake lever; Checking of brake fluid level - front brake; Refilling the front brake fluid reservoir*; Checking the front brake pads
ENGLISH 26 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustingscrew 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 di...
Page 28 - Changing the basic position of the foot brake pedal*; Checking rear brake fluid level; Refilling the rear brake fluid reservoir*; Checking the rear brake pads
ENGLISH 27 Changing the basic position of the foot brake pedal* The basic position of the foot brake pedal can be altered by turning the stoproller 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...
Page 29 - Dismounting and mounting the front wheel (LC4); Dismounting and mounting the front wheel (LC4 Supermoto)
ENGLISH 28 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 30 - Dismounting and mounting the rear wheel; Checking the shock absorption rubbers in the rear hub *
ENGLISH 29 Dismounting and mounting the rear wheel To remove the rear wheel, jack the motorcycle up on its frame so that therear 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 b...
Page 31 - front; T I R E S - A I R P R E S S U R E; Checking spoke tension; Changing the wheel size
ENGLISH 30 640 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 32 - Battery; Charging the battery; VOLT
ENGLISH 31 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. Simplykeep the battery poles clean and slightly grease them with an acid-freegrease if necessary. Removing the battery:Remove screws 1 and swing ret...
Page 33 - Fuses; Exchanging the headlight lamp; Replacing the parking-light bulb
ENGLISH 32 Fuses Fuse box A is 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 ...
Page 34 - Exchanging the brake light and tail light bulb
ENGLISH 33 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 35 - Checking the cooling liquid level; Cleaning the air filter *
ENGLISH 34 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 36 - Adjusting the throttle cable *; Changing the original position of the clutch lever
ENGLISH 35 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 37 - Checking and adjusting the choke cable play *; Adjust idling speed *
ENGLISH 36 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 38 - Draining the carburetor float chamber *; Engine oil; Checking the engine oil level; TEMPERATUR
ENGLISH 37 Draining the carburetor float chamber * Following every wet-cleaning procedure, the float chamber of thecarburetor should be drained in order to remove any water that may havepenetrated into it. Water in the float chamber causes engine malfunction.Carry out this job with the engine being ...
Page 39 - Oil circuit
ENGLISH 38 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 40 - Changing oil filter *
ENGLISH 39 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 41 - TROUBLE SHOOTING
ENGLISH 40 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 44 - RE-INITIATION AFTER TIME OF STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
ENGLISH 43 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 45 - STANDARD ADJUSTMENT - FORK; SUPERMOTO
ENGLISH 44 TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2003 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork W hite P ower – U p S ide D own 4357 MXMA W hite P ower – U p S ide D own 4860 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) 265 / 310 mm (1...
Page 46 - TIGHTENING TORQUES - CHASSIS
ENGLISH 45 Collar nut front axle M16x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top M10 45 Nm Shock absorber bottom M10 45 Nm Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10 Nm Screw brake caliper front (LC4) M8 Loctite 243 + 25 Nm Screw brake caliper front (Supermoto...
Page 48 - BASIC CARBURETOR SETTING
ENGLISH 47 BASIC CARBURETOR SETTING Type BST40-266 Main jet 152,5 Needle jet X-6 689 Idling jet 45 Jet needle 6G5 Needle clip pos. f. top 3. from top Mixt. adj. screw open 2,25 640 LC4 640 LC4 Supermoto
Page 49 - HEAD WORD INDEX
ENGLISH 48 page Adjisting of free travel at the hand brake lever ....................26 Adjust idling speed ..............................................................36 Adjusting the throttle cable .................................................35 Battery .........................................
