KTM ENDURO 640 LC4 Owner's Manual
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KTM ENDURO 640 LC4 Owner's Manual

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OWNER'S MANUAL
2006
640 LC4 ENDURO
640 LC4 SUPERMOTO
ART. NR. 3.211.78 EN

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Summary of Contents for KTM ENDURO 640 LC4

  • Page 1 OWNER’S MANUAL 2006 640 LC4 ENDURO 640 LC4 SUPERMOTO ART. NR. 3.211.78 EN...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
  • Page 3 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.

  • Page 4: Important Limited Warranty And Limited Guarantee Information

    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.

  • Page 5: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......13 Instructions for initial operation ....13 Running in the LC4 models .

  • 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: Operation Instruments

    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.

  • Page 8: Multi-Functional Digital Speedometer

    Display [2] shows all of the information that may be of interest to you. 5 dis- play modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition. Display...

  • Page 9: Setting Options In The Display

    OPERATION INSTRUMENTS 10 sec » Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the dis- play. The display can be adapted to the respective country on long-distance trips.

  • Page 10: Cooling Liquid Temperature Display

    OPERATION INSTRUMENTS 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) » 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 cooling liq- uid has reached a temperature of approx.

  • Page 11: Combination Switch

    OPERATION INSTRUMENTS » Combination switch The rocker switch LIGHTS [1] actuates 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.

  • Page 12: Fuel Tap

    In this position the fuel tap is closed. No fuel may flow to the carburetor. When using the motorcycle, the twist grip must be set to the ON posi- tion. Now fuel may flow to carburetor. In this position the tank emp- ties down to the fuel reserve of approx.

  • Page 13: Compression Damping Of Fork

    OPERATION INSTRUMENTS » 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 compres- sion can be adjusted.

  • Page 14: General Tips And Warnings For Starting The Motorcycle

    Accessory parts and baggage can significantly decrease a motor- cycle's driving stability. Please observe the following warnings. – ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC.

  • Page 15: 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, as com- plete failure of the braking system can be avoided.

  • Page 16: Starting When The Engine Is Warm Or Hot

    KTM dealer. NOTE: If you have trouble starting the motorcycle, this could be due to old fuel in the float chamber. The easily inflammable components of the new fuels evap- orate during longer periods of standstill.When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber.

  • Page 17: Kickstart Instructions

    - CAUTION SCALDING HAZARD! - AND CHECK THE COOLING LIQ- UID LEVEL. DO 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 REME- DIED.

  • Page 18: Stopping And Parking

    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.

  • Page 19: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE 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...
  • Page 20 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! VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC...

  • Page 21: Maintenance Work On Chassis And Engine

    ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFES- SIONAL. 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 22: Removal Of Seat (Lc4 Supermoto)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Removal of seat (LC4 Supermoto) Actuate the lever [1] while lifting the back of the seat [2]. When you mount the seat, make sure the retaining brackets are fastened to the seat. Tool set (LC4 Supermoto) The tool set [3] is located under the seat.

  • Page 23: Bleeder Screws For Telescopic Fork

    [1] 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.

  • Page 24: Changing The Spring Preload Of The Shock Absorber

    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.

  • Page 25: Checking Chain Tension

    IF 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 POS- SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.

  • Page 26: Chain Maintenance

    OF CONTROL. – THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL. – NEVER MOUNT A NORMAL CHAIN JOINT.

  • Page 27: General Informations About Ktm Disc Brakes

    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 28: Adjusting Of Free Travel At The Hand Brake Lever (Lc4 Enduro)

    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. Refilling the front brake fluid reservoir * Loosen screws [4] and remove lid [5] and membrane [6].

  • Page 29: Checking The Front Brake Pads (Lc4 Enduro)

    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.

  • Page 30: Checking Rear Brake Fluid Level

    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. 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.

  • Page 31: Dismounting And Mounting The Front Wheel (Lc4 Enduro)

    15 Nm. – IF 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 BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 32: Dismounting And Mounting The Rear Wheel

    – IF 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 WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIV- ING BEHAVIOR OF YOUR MOTORCYCLE.

  • Page 33: Tires, Air Pressure

    2.2 bar – Do not mount tires which have not been approved by KTM. Other tires 2.4 bar could have adverse effects on the way your motorcycle rides.

  • Page 34: Battery

    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, starta- bility and the generator capacity.

  • Page 35: Fuses

    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. » LC4 ENDURO 20 Ampere protects all power consumers against short circuits.

  • Page 36: Exchanging The Brake Light And Tail Light Bulb (Lc4 Supermoto)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Exchanging the brake light and tail light bulb (LC4 Supermoto) Remove seat. Disengage retaining clip [1] and take bulb out of reflector. When changing the brake-light lamp, simply pull it out of the holder. Slightly depress the bulb, turn it approx.

  • Page 37: Exchanging The Headlight Lamp (Lc4 Supermoto)

    Make a mark on a light wall behind a level surface at a height corresponding to the center of the headlight. Position your motorcycle loaded ready for the trip 5 meters (16,4 ft) away from the wall and switch on the low beam. The light/dark cut-off line should be 5 cm (2 in) under the mark (see drawing).

  • Page 38: Cooling System

    EXAMINE THE COOLING LIQUID LEVEL 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 39: Cleaning The Air Filter (Lc4 Enduro)

    – 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.

  • Page 40: Exhaust System (Lc4 Supermoto)

    If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungsfluid 75), available from your authorized KTM workshop. KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.

  • Page 41: Checking And Adjusting The Choke Cable Play

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking and adjusting the choke cable play * The choke lever must always have a play of approx. 4 mm (0.16 in). IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED.

  • Page 42: Activating The Ignition Curve For Low-Octane Fuel

    » MAINTENANCE WORK ON CHASSIS AND ENGINE 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 [1] is located on a brown-black cable near the digital box.

  • Page 43: Engine Oil

    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 tem- 10W/50 peratures 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 44: Oil And Screen Filter Change, Bleeding Of The Oil System

    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 45: Changing Oil Filter

    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.

  • Page 46: 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 47 Check vacuum hose and venting hose of carburetor for cor- rect position (no kinks) Air filter very dirty Clean or replace air filter, contact a KTM dealer Valve clearance to small Have valve clearance adjusted Loss of compression because hand...
  • Page 48 Check connections and cables. echarge the battery according to the relevant instructions. Remove seat and check voltage regulator connections; volt- age regulator and generator should be checked by a KTM dealer. Replace the main fuse under the seat Check the sensor cable for damage and replace it if necessary.

  • Page 49: Cleaning

    – 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.

  • Page 50: Technical Specifications - Chassis

    TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ENDURO Frame Central chrome-moly-steel frame Fork WP Suspension – Up Side Down 4357 MXMA Wheel travel front/rear 275 / 275 mm Rear suspension Central shock absorber (WP BAVP) with PRO-LEVER linkage to rear- swing-arm with needle bearing Disc brake with carbon-steel brake disc, Front brake 2-piston brake caliper floated...
  • Page 51 TECHNICAL SPECIFICATIONS - CHASSIS 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 (Enduro) Screw brake caliper front (Supermoto) Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Ball joint for push rod...

  • Page 52: Technical Data - Engine

    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).

  • Page 53: Head Word Index

    Fuses ........34 General informations about KTM disc brakes ..26 General tips and warnings for starting the motorcycle .

  • Page 54: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAMM position light ye-bl br-bl bu-bl or-bl gn-bl ignition coil bu-wh re-gn re-gn bu-wh or-bl bu-bl br-bl br-bl headlight front multi-func.-digital-speedometer brake switch ye-bu ye-bu sidestand switch gn-wh ye-bu rear light/brakelight speed sensor gn-bl gn-bl gn-re ye-br gn-br bu-re bu-bl...
  • Page 55 » SCHALTPLAN WIRING DIAGRAMM g i l c t i c t i o i t e l l e l l c t i c t i l i k c t i c t i c t i c t i g i l c t i...
  • Page 56 » SCHALTPLAN WIRING DIAGRAMM ye-bl br-bl bu-bl or-bl gn-bl ignition coil bu-wh re-gn re-gn bu-wh or-bl bu-bl br-bl br-bl rear light/brakelight headlight front multi-func.-digital-speedometer brake switch ye-bu ye-bu sidestand switch gn-wh ye-bu speed sensor gn-bl gn-bl gn-re ye-br gn-br bu-re bu-bl br-pi bl-bu...
  • Page 57 » SCHALTPLAN WIRING DIAGRAMM g i l c t i c t i o i t e l l e l l c t i c t i l i k c t i c t i c t i c t i g i l c t i...
  • Page 58 » SCHALTPLAN WIRING DIAGRAMM ENGLISH headlight parking light turn indic left fr turn indic left fr ignition controll ON high beam indicator turn indicator multip cont plug (2) multip cont plug (3) multip cont plug (4) stoplight switch f stoplight switch r horn turn indicator spark plug...
  • Page 59 ENGLISH headlight parking light turn indic left fr turn indic left fr ignition controll ON high beam indicator turn indicator multip cont plug (2) multip cont plug (3) multip cont plug (4) stoplight switch f stoplight switch r horn turn indicator spark plug ignition coil generator...
  • Page 60 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

640 lc4 enduro 2006640 lc4 supermoto 2006

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