KTM 640 LC4 Adventure Owner's Manual
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KTM 640 LC4 Adventure Owner's Manual

2006
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OWNER'S MANUAL
2006
640 LC4 ADVENTURE
ART. NR. 3.211.79 EN

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  • Page 1 OWNER’S MANUAL 2006 640 LC4 ADVENTURE ART. NR. 3.211.79 EN...
  • Page 2 KTM may stop manufacturing cer- tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con- tain 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

    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 .......5 Adjusting of free travel at the hand brake 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

    » OPERATION INSTRUMENTS Hand brake lever The hand brake lever [1] is mounted on the handlebar on the right and actu- ates the front wheel brake.The adjusting screw [B] is used to change the orig- inal position of the hand brake lever (see maintenance work on chassis and engine).

  • Page 8: Multi-Functional Digital Speedometer

    » OPERATION INSTRUMENTS 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 dis- play modes can be selected with the MODE button.

  • Page 9: Setting Options In The Display

    » OPERATION INSTRUMENTS Setting options in the display 10 sec 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 Cooling liquid temperature display The temperature display [1] 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 liq- 110°C (230°F) 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: Shift Lever

    » OPERATION INSTRUMENTS 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. When using the motorcycle, the twist grip must be set to the ON posi- tion.

  • 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 compression can be adjusted.

  • Page 14: Baggage Carrier / Grips

    » OPERATION INSTRUMENTS Baggage carrier / Grips The baggage carrier [1] may be loaded with up to 10 kg. The two lateral hoops [2] serve as handles for the passenger Footrests The passenger footrests [3] fold up.

  • Page 15: General Tips And Warnings For Starting The Motorcycle

    – ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPER- roughened.

  • 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: If you have trouble starting the motorcycle, this could be due to old fuel in the float chamber.

  • Page 18: Starting When The Engine Is Warm Or Hot

    ESCAPE. CAUTION SCALDING HAZARD! - AND CHECK THE COOL- ING LIQUID LEVEL. – DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEAL- ERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.

  • Page 19: Braking

    “SPONGY” (TOO MUCH PLAY), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition.

  • Page 20: Refueling

    » DRIVING INSTRUCTIONS Refueling In the condition at delivery, the LC4 engine requires unleaded premium-grade fuel with at least 95 octane (ROZ) (USA=Premium RON91). If using lower octane fuel, it is easy to change over to the pre-programmed ignition curve for 80 - 94 octane (ROZ) (see activating the ignition curve for low-octane fuel).

  • Page 21: Periodic Maintenance Schedule

    » PERIODIC MAINTENANCE SCHEDULE 2nd Service after 1st Service 640 LC4 5000 km, then A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! after ADVENTURE every 5000 km 1000 km 2006 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 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! 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!

  • 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 SERV- ICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.

  • Page 24: Checking And Adjusting Steering Head Bearing

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking and adjusting steering head bearing * Check steering head bearing for play periodicaly. To check this put motorcy- cle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward.

  • Page 25: Changing The Spring Preload Of The Shock Absorber

    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. NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER.

  • Page 26: 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 27: Chain Maintenance

    OUT 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 ORIGINAL RIVETING TOOL. – NEVER MOUNT A NORMAL CHAIN JOINT.

  • Page 28: 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 29: Adjusting Of Free Travel At The Hand Brake Lever

    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 [2] and remove lid [3] and membrane [4].

  • Page 30: Changing The Basic Position Of The Brake Pedal

    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

    15 Nm. – IF YOU DO NOT HAVE A TORQUE WRENCH TO MOUNT THE WHEEL, HAVE THE TORQUES CORRECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POS- SIBLE. A LOOSE AXLE PASSAGE CAN CAUSE THE MOTORCYCLE'S HANDLING PERFORMANCE TO BECOME INSTABLE.

  • 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

    – Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES 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

    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. UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE “REPAIRED”.

  • 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

    ATURE IS 98°C (208,4°F) AND THE IGNITION IS ON. IF THE FAN IS NOT WORK- ING, AND THERE APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY THING YOU CAN DO IS TO DRIVE ON TO YOUR NEAREST KTM GARAGE AT THE LEAST POSSIBLE ENGINE LOAD.

  • Page 38: Cleaning The Air Filter

    – DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY MOTOREX (BIO DIRT REMOVER AND LIQUID BIO POWER) FOR AIR FILTER MAINTENANCE.

  • Page 39: Changing The Original Position Of The Clutch Lever

    If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 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 40: 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 41: Draining Of Float Chamber Of The Carburetor

    32°F 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- 5W/40 10W/50 peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • 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

    » MAINTENANCE WORK ON CHASSIS AND ENGINE BLEEDING OF THE OIL SYSTEM 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.

  • 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 SHOOTING TROUBLE CAUSE REMEDY Engine switches on but does Spark plug connector or spark Remove the spark plug, connect the ignition wire, apply the not start plug 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 SHOOTING 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...

  • 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.

  • Page 49: Technical Specifications - Engine

    Only use fully synthetic engine oils that meet the JASO MA quality require- JASO T903 MA ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). TEMPERATUR 0°C...
  • Page 50 » TECHNICAL SPECIFICATIONS – ENGINE TIGHTENING TORQUES – ENGINE 640 LC4 ADVENTURE Hexagon nut at primary gear M20x1.5 Loctite 243 + 170 Nm Collar nut flywheel M16x1.25 left 80° C + 150 Nm Hexagon nut for inner clutch hub M18x1.5...

  • Page 51: Technical Specifications - Chassis

    » TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 640 LC4 ADVENTURE Frame Central chrome-moly-steel frame Fork WP Suspension Up Side Down MXMA 4860 Wheel travel front/rear 275/300 mm (10.5/12 in) Rear suspension Central shock absorber (WP Suspension BAVP4681) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake, 2 perforated brake discs Ø...
  • Page 52 » TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 640 LC4 ADVENTURE Collar nut front axle M16x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top/bottom 45 Nm Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10 Nm...

  • Page 53: Head Word Index

    Battery ........33 General informations about KTM disc brakes ..27 Bleeder screw front fork .

  • Page 54: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAM headlight tachometer front multi-func.-digital-speedometer brake switch speed sensor gn-bl ye-bl gn-bl br-bl head light flascher gn-re ye-bu ye-br gn-br bu-re bu-bl gn-bl br-pi bu-bl ye-bu or-bl bl-bu ignition coil bl-wh bl-or bu-wh ye-br ye-wh re-ye re-gn fuse box ye-re ye-bu...
  • Page 55 » SCHALTPLAN WIRING DIAGRAM c t i c t i c t i c t i c t i o i t e l l e l l c t i g i l g i l c t i l i k c t i c t i...
  • Page 56 » SCHALTPLAN WIRING DIAGRAM 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 57 » SCHALTPLAN WIRING DIAGRAM 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...
  • Page 58 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

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640 lc4 adventure 2006

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