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Table of Contents
Related Manuals for KTM 640 LC4 SUPERMOTO 2003
Summary of Contents for KTM 640 LC4 SUPERMOTO 2003
- 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 TECHNICAL SPECIFICATIONS...
- 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: 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
Chain maintenance............24 Chassis number ..............5 Chain wear..............24 Engine number, engine type..........5 General information on KTM disc brakes ......25 OPERATION INSTRUMENTS ..........5 Adjisting of free travel at the hand brake lever ....26 Clutch lever ..............5 Checking of brake fluid level - front brake......26 Hand decompression lever..........5... -
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: 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 set- tings 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 8: Seeting 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 9: Indicator Lamps
Cooling liquid temperature display The temperature display is shown in 7 bars. The more bars that light up, 110°C (230°F) the hotter the cooling liquid. When the lowest bar lights up, the cooling 100°C (212°F) liquid has reached a temperature of approx. 50°C. Each additional bar 90°C (194°F) represents 10°C more. -
Page 10: Combination Switch
Combination switch The rocker switch LIGHTS actuates the high beam or low beam. = High-beam light = Low-beam light 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 The light signal (high beam) is actuated with button Starter tip switch, emergency OFF tip switch, light switch Use the starter tip switch... -
Page 11: Fuel Tap
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 tank empties down to the fuel reserve of approx. -
Page 12: 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 13: 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 14: 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 complete failure of the braking system can be avoided. -
Page 15: 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 LC4 / LC4 SUPERMOTO: This motorcycle is equipped with a safety starter system. The engine can only be started when the transmission is switched to idle or the clutch lever is pulled, respectively. -
Page 16: Kickstart Instructions
Let clutch lever O NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING go again and open throttle. If you turned on the choke, make KTM’ SYSTEM OWEVER CALL ON ONE OF S DEALERS AS SOON AS sure you turn it off again as soon as engine is warm. -
Page 17: Stopping And Parkling
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 an area where the ground is firm, and lock the motorcycle. WARNING –... -
Page 19: Periodic Maintenance-Schedule
640 LC4 PERIODIC MAINTENANCE SCHEDULE 640 LC4 SUPERMOTO 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 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 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 21: Maintenance Work On Chassis And Engine
ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFESSIONAL. IN THE INTEREST OF YOUR OWN SAFETY, HAVE THESE PROCEDURES CARRIED OUT AT A KTM SERVICE STATION! AT KTM YOUR MOTORCYCLE WILL RECEIVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS. -
Page 22: 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 23: 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 24: 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 illustration) Now, the distance between chain and swingarm should be 0 mm. -
Page 25: 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 (Shell Advance Bio Chain). -
Page 26: General Information On Ktm Disc Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Shell Advance Brake DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. -
Page 27: Adjisting 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 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 28: Changing The Basic Position Of The Foot Brake Pedal
Changing the basic position of the foot brake pedal* The basic position of the foot brake pedal can be altered by turning the stop roller . The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside, the foot brake pedal must have 3-5 mm (0,12–0,20 in) of free play, before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot... -
Page 29: Dismounting And Mounting The Front Wheel (Lc4)
Dismounting and mounting the front wheel (LC4) To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws on the left fork leg. Then loosen the collar nuts before loosening the clamp screws on the right fork leg. -
Page 30: Dismounting And Mounting The Rear Wheel
Dismounting and mounting the rear wheel To remove the rear wheel, jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Loosen the collar nut , remove chain tensioner , 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 31: Tires, Air Pressure
(see illustration). A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING –... -
Page 32: Battery
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. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: Remove screws and swing retaining bracket and voltage regulator out of... -
Page 33: 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 34: Exchanging The Brake Light And Tail Light Bulb
Exchanging the brake light and tail light bulb Remove the cap on the underside of the license plate retainer. Turn the lamp socket approximately 30° counterclockwise and pull it out of the tail light housing. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket. -
Page 35: Checking The Cooling Liquid Level
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 36: Adjusting The Throttle Cable
4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell Naturelle HF-E15).Biodegradable hydraulic oil is available from your KTM dealer (50ml). CAUTION USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL... -
Page 37: Checking And Adjusting The Chocke 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. Push the choke lever all the way to the front and slide the protecting cap from the adjusting part Loosen the lock nut and correct the play by turning the adjusting part. -
Page 38: Draining The Carburetor Float Chamber
Draining the carburetor float chamber * Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes engine malfunction. Carry out this job with the engine being cold. Close the fuel tap. -
Page 39: 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 40: 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 41: 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 42 Carburetor leaking Check vacuum hose and venting hose of carburetor for correct 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 43 The battery isn’t charged by the Remove seat and check voltage regulator connections; voltage generator because regulator and generator should be checked by a KTM dealer. Main fuse melted through Replace the main fuse (1) under the seat No values are visible in the Tripmaster display.
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Page 44: 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 45: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2003 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power – Up Side Down 4860 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) - Page 46 TIGHTENING TORQUES - CHASSIS Collar nut front axle M16x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top 45 Nm Shock absorber bottom 45 Nm Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10 Nm Screw brake caliper front (LC4) Loctite 243 + 25 Nm Screw brake caliper front (Supermoto)
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Page 47: Technical Specifications - Engine
TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2003 Engine 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... - Page 48 BASIC CARBURETOR SETTING 640 LC4 640 LC4 Supermoto Type BST40-266 Main jet 152,5 Needle jet X-6 689 Idling jet Jet needle Needle clip pos. f. top 3. from top Mixt. adj. screw open 2,25...
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Page 49: Head Word Index
Braking ................15 Fuel tap ................10 Breather plug front fork ............21 Fuses ..................32 Chain maintenance .............24 General information on KTM disc brakes ......25 Chain wear .................24 General tips and warnings for starting the motorcycle..12 Changing oil filter ..............39 Hand brake lever ..............5 Changing the basic position of the foot brake pedal ...27... - Page 53 321056...