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Related Manuals for KTM 640 LC4 ADVENTURE 2003
Summary of Contents for KTM 640 LC4 ADVENTURE 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 ............26 Chassis number............5 Chain wear ..............26 Engine number, engine type ........5 General information about KTM disc brakes....27 Adjusting of free travel at the hand brake lever..28 OPERATION INSTRUMENTS ..........5 Checking of brake fluid level - front brake ....28 Clutch 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: 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 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 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: 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 11: 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 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 com- pression can be adjusted. -
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: HIS MOTORCYCLE IS EQUIPPED WITH A SAFETY STARTER SYSTEM... -
Page 18: Kickstart Instructions
AND CHECK THE COOLING LIQUID LEVEL – D O NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COO KTM’ LING 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 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 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 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 APPRO- PRIATELY 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 scr- 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 Information About Ktm Disc Brakes
KTM dealer immediately. BRAKE FLUID: KTM motorcycle braking systems are filled with DOT 4 brake fluid (Motorex Brake Fluid DOT 4). DOT 4 brake fluid is based on glycol ether and is of an amber color. Always use DOT 4 or DOT 5.1 brake fluid to refill. -
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 screw . In this way, the position of the point of pressure (i.e., the resi- stance 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: Check The Rear Brake Fluid Level
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 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 32: Checking The Shock Absorbtion Rubbers In The Rear Hub
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. WARNING – D KTM. O O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY THER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES –... -
Page 33: Checking Spoke Tension
(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 34: 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 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 Blub
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 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: 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 40: 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 AN UNE... -
Page 41: Draining Of Float Chamber Of The Carburetor
Draining of float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carbure- tor should be drained in order to remove any water that may have penetra- ted into it. Water in the float chamber leads to engine malfunction. Wait until the engine is cold before commencing to perform the worksteps indicated below. -
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 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 46 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. No values are visible in the Main fuse melted through Replace the main fuse (1) under the seat Tripmaster display.
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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 Specifications - Engine
TECHNICAL DATA – ENGINE 640 LC4 ADVENTURE 2003 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 2003 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 BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø... - Page 52 TIGHTENING TORQUES - CHASSIS 640 LC4 ADVENTURE Collar nut front axle M16x1,5 40 Nm (30ft.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) Screw brake caliper front Loctite 243 + 25 Nm...
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Page 53: Head Word Index
Chain maintenance .............26 Chassis number..............5 Chain wear .................26 Engine number, engine type ..........5 General information about KTM disc brakes......27 Operation instruments ............5 Adjusting of free travel at the hand brake lever....28 Clutch lever................5 Checking of brake fluid level - front brake ......28 Hand decompression lever ............5... - Page 59 321057...