Related Manuals for KTM 640 LC4 ADVENTURE
Summary of Contents for KTM 640 LC4 ADVENTURE
- Page 1 BEDIENUNGSANLEITUNG2004 640 LC4 ADVENTURE OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.210.86...
- Page 2 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT...
- Page 3 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.
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Page 4: Important Limited Warranty And Limited Guarantee Information
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. -
Page 5: Table Of Contents
OPERATION INSTRUMENTS ......5 General informations about KTM disc brakes ..27 Clutch lever . -
Page 6: Serial Number Locations
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. -
Page 7: Hand Brake Lever
Hand brake lever The hand brake lever is mounted on the handlebar on the right and actuates the front wheel brake.The adjusting screw is used to change the original position of the hand brake lever (see maintenance work on chassis and engine). -
Page 8: Multi-Functional Digital Speedometer
Multi-functional digital speedometer The universal instrument is divided into 3 parts. Use the MODE and SET button to change the display and the basic settings in the display. Display shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. -
Page 9: Setting Options In The Display
Setting options in the display 10 sec KILOMETERS OR MILES. 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 button for approx. -
Page 10: Cooling Liquid Temperature Display
Cooling liquid temperature display The temperature display is shown in 7 bars. The more bars that light up, 120°C (248°F) the hotter the cooling liquid. When the lowest bar lights up, the cooling 110°C (230°F) liquid has reached a temperature of approx. 40°C (104°F). When the upper 100°C (212°F) bar lights up 120°C (248°F), all of the bars will start to blink and the red 70°C (158°F) -
Page 11: Combination Switch
Combination switch The rocker switch LIGHTS actuates the high beam or low beam. = High-beam light = Low-beam light = The light signal (high beam) is actuated with button The indicator switch returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button Starter tip switch, emergency OFF tip switch, light switch Use the starter tip switch... -
Page 12: Shift Lever
Fuel tap A on the left side of the tank has 3 positions. OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. -
Page 13: Compression Damping Of Fork
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 . By using the knob (COM), the degree of damping of the compression can be adjusted. -
Page 14: Baggage Carrier / Grips
Baggage carrier / Grips The baggage carrier may be loaded with up to 10 kg. The two lateral hoops serve as handles for the passenger Footrests The passenger footrests 3 fold up. -
Page 15: General Tips And Warnings For Starting The Motorcycle
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE LEVER OF VEHICLE jobs (see Customer Service Manual). DRIVERS ALWAYS WEAR A HELMET... -
Page 16: Driving Instructions
If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist garage, as complete failure of the braking system can be expected. -
Page 17: Starting When The Engine Is Cold
– 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: This motorcycle is equipped with a safety starting system. The engine can only be started if the transmission is in neutral or the clutch lever is pulled. -
Page 18: Starting The Engine With The Kickstarter
AND CHECK THE COOLING STAND LIQUID LEVEL – D O NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE KTM’ COOLING SYSTEM OWEVER CALL ON ONE OF S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED –... -
Page 19: Stopping And Parking
Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Close fuel tap. Park on solid ground and lock the vehicle. WARNING – M OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING ENGINE RADIATORS EXHAUST EXHAUST SYSTEM... -
Page 20: Activating The Ignition Curve For Low-Octane Fuel
Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (ROZ)(USA=Premium RON91) is not available, you can easily activate the corresponding ignition curve. A plug and socket connection on a brown/black cable is located on the right side of the vehicle next to the CDI box . -
Page 21: Periodic Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE 640 LC4 ADVENTURE 1. Service 2. Service after after 5000 km, then A washed motorcycle can be checked more quickly which saves money! 1000 km every 5000 km or once a year Change engine oil, oil filter, and fine filter... - Page 22 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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...
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Page 23: Maintenance Work On Chassis And Engine
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. 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. -
Page 24: Checking And Adjusting Steering Head Bearing
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 of the top triple clamp and turn steering stem bolt clockwise until there is no more play. -
Page 25: Changing The Spring Preload Of The Shock Absorber
Measure the distance between the two discs at various points around their min. 2,5 mm 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... -
Page 26: Checking Chain Tension
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 illustr.) Now, the distance between chain and swingarm should be 0 mm. -
Page 27: Chain Maintenance
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). -
Page 28: General Informations About Ktm Disc Brakes
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. -
Page 29: Adjusting Of Free Travel At The Hand Brake Lever
Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting min. 3 mm screw . 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. -
Page 30: Changing The Basic Position Of The Brake Pedal
Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set. -
Page 31: Dismounting And Mounting The Front Wheel
Dismounting and mounting the front wheel * Jack the motorcycle up at the underride protection until the front wheel no longer touches the ground. Loosen the collar screw and the clamp screws at both fork leg axle passages. Unscrew the collar screw approx. 8 turns, pressing your hand against the collar screw to push the axle passage out of the fork leg and remove the collar screw. -
Page 32: Dismounting And Mounting The Rear Wheel
Dismounting and mounting the rear wheel* Jack the motorcycle up by frame so that the rear wheel no longer touches the ground. Loosen the collar nut , hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held. -
Page 33: Tires, Air Pressure
PERFORMANCE VIBRATION AT HIGHER SPEEDS Approved tires for 640 LC4 Adventure (as of July 2003) BRIDGESTONE ..TW 301/302 METZELER ....E... -
Page 34: Battery
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). -
Page 35: Fuses
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 NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE “... -
Page 36: Exchanging The Brake Light And Tail Light Bulb
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. Removing the tank * Removing the seat (see page 22) -
Page 37: Cooling System
CAUTION SCALDING HAZARD! Do not drive on, until there is sufficient liquid in the cooling system. Go to your nearest KTM garage and get it seen to. If you drive with the cooling liquid temperature warning light on, you will cause even more damages to the engine. -
Page 38: Cleaning The Air Filter
Check whether the air filter is positioned correctly and mount the filter box cover. CAUTION – D O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE . KTM THE FOAM RECOMMENDS THE PRODUCTS MADE BY IR FOR AIR FILTER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER –... -
Page 39: Changing The Original Position Of The Clutch Lever
. The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), available from your authorized KTM workshop. CAUTION USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL... -
Page 40: Checking And Adjusting The Choke Cable Play
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. CAUTION F THERE IS NO PLAY IN THE CHOKE CABLE THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED HIS RESULTS IN HIGH FUEL CONSUMPTION UNEVEN RUNNING ENGINE... -
Page 41: Draining Of Float Chamber Of The Carburetor
Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). 5W/40 10W/50 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). Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. -
Page 42: Oil Circuit
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. -
Page 43: Changing Oil Filter
To facilitate bleeding of the oil system, we have added a hose connection piece and a plastic hose to the set of tools. Take an empty oil can (1 liter) and drill a 7 mm-diameter hole into the lid. Screw the hose connection piece into the lid from the outside, and secure it from the inside with the M8 hexagon nut. -
Page 44: Trouble Shooting
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. - Page 45 TROUBLE CAUSE REMEDY Engine switches on but does Spark plug connector or spark plug Remove the spark plug, connect the ignition wire, apply the not start is defective spark plug to the ground (bright area on the engine) and start; a strong spark should be visible at the spark plug –...
- Page 46 TROUBLE CAUSE REMEDY Engine gets too hot Not enough cooling liquid in the Add cooling liquid (see maintenance work), check the cooling cooling system system for leaks Radiator fins are heavily soiled Clean the radiator fins with a water jet Foam has formed in the cooling Replace the cooling liquid, use a brand-name antifreeze system...
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Page 47: Cleaning
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 EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH... -
Page 49: Technical Data - Engine
TECHNICAL DATA – ENGINE 640 LC4 ADVENTURE 2004 Type 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,5 : 1 Fuel unleaded premium gasoline with a least RON 95... - Page 50 TIGHTENING TORQUES - ENGINE 640 LC4 M20x1,5 Loctite 243 + 170 Nm (125 ft.lb) Hexagon nut at primary gear Collar nut flywheel M16x1,25 left 80° C + 150 Nm (110 ft.lb) Hexagon nut for inner clutch hub M18x1,5 Loctite 243 + 80 Nm (59ft.lb) Kickstarter stop screw M12x1,5...
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Page 51: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2004 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear 275/300 mm (10,5/12 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake, 2 perforated brake discs Ø... - Page 52 TIGHTENING TORQUES - CHASSIS 640 LC4 ADVENTURE Collar nut front axle M24x1,5 60 Nm (44ft.lb) Collar nut rear axle M20x1,5 80 Nm (59ft.lb) Shock absorber top/bottom 45 Nm (33ft.lb) Collar screws brake disk front/rear M6 (10,9) Loctite 243 + 10 Nm (7ft.lb)
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Page 53: Head Word Index
Battery ........33 General informations about KTM disc brakes ..27 Bleeder screw front fork . - Page 56 ENGLISH DEUTSCH ITALIANO Aditional instruments (roadbook;GPS;...) Externe Instrumente Strumenti supplementari Battery Batterie Batteria Clutch switch Kupplungsschalter Interruttore frizione Cooling fan Lüftermotor Motorino ventola Diode Diode Diodo Electronic Power Control (EPS) Electronic Power Control (EPS) Electronic Power Control (EPS) Flasher relay Blinkerrelais Relè...
- Page 58 ENGLISH FRANCAIS ESPANOL Aditional instruments (roadbook; GPS;...) Accessoires Instrumentos externos Battery Batterie Batería Clutch switch Contacteur d’embrayage Interruptor de embrague Cooling fan Ventilateur Motor del ventilador Diode Diode Diodos Electronic Power Control (EPS) Electronic Power Control (EPS) Electronic Power Control (EPS) Flasher relay Relais de clignotants Relé...
- Page 59 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...