KTM 640 LC4 Owner's Manual
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- Owner's manual (60 pages) ,
- Owner's manual (53 pages) ,
- Owner's handbook manual (43 pages)
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Summary of Contents for KTM 640 LC4
- Page 1 BEDIENUNGSANLEITUNG2004 640 LC4 ENDURO 640 LC4 SUPERMOTO OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.210.85...
- Page 2 BODY AND YOUR LIFE. IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number...
- 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
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The 640 LC4 Enduro model was designed to resist the usual wear and tear of normal use on the road and easy terrain (unpaved roads). The 640 LC4 Supermoto model is designed for regular on-road service but not for use off of paved roads. -
Page 5: Table Of Contents
Chain maintenance...24 Chain wear...24 INDEX Page General information on KTM disc brakes ...25 Adjisting of free travel at the hand brake lever ...26 Changing the basic position of the handbrake lever...26 Checking of brake fluid level - front brake...26 Refilling the front brake fluid reservoir...26 Checking the front brake pads...27... -
Page 6: Serial Number Locations
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 7: Multi-Functional Digital Speedometer
Display shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps provide additional information on the motorcycle's running condition. Display TEST When you switch on the ignition, all of the display elements will light up for 1 second for the function test. -
Page 8: Seeting Options In The Display
10 sec Setting options in the display 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: Cooling Liquid Temperature Display
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 the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning lamp will light up. -
Page 10: 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 The emergency off switch... -
Page 11: 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
Holding bars The passenger can hold on to the holding bars on the rear end of the vehicle. (COM), the degree of damping of the (640 LC4) (640 LC4 Supermoto) (640 LC4) (640 LC4 Supermoto) (640 LC4) (640 LC4 Supermoto) -
Page 13: General Tips And Warnings For Starting The Motorcycle
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read these operating instructions carefully before your first ride. – Enter the chassis, engine and key numbers on page 1. -
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
6 Do not accelerate; operate starter button 7 If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Take the motorcycle off of the main stand or side stand. – T O AVOID INJURIES KICKSTARTER –... -
Page 16: Kickstart Instructions
LEAD TO ENGINE DAMAGE THROTTLE LEVER – N EVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR – THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT TEMPERATURE HAS REACHED... -
Page 17: Stopping And Parkling
(see illustration). Make sure that the ground is solid and that your motorcycle is standing securely. HE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY... -
Page 19: Periodic Maintenance-Schedule
Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN AINTENANCE WORK DONE BY... -
Page 20: Periodic Maintenance Schedule
640 LC4 PERIODIC MAINTENANCE SCHEDULE 640 LC4 SUPERMOTO 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... -
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. 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: 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... -
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 To check, jack up the motorcycle on the center stand or frame until it no longer touches the ground. Press the chain up approx. 30 mm behind the end of the chain sliding component. The chain should barely touch the swing arm when the upper chain part is tensioned. -
Page 25: Chain Maintenance
O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL CAUTION HEN MOUNTING THE CHAIN JOINT... -
Page 26: Brake Pads
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 27: Adjisting Of Free Travel At The Hand Brake Lever
min. 3 mm Adjusting of free travel at the hand brake lever (LC4) 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: Checking The Front Brake Pads
Checking the front brake pads (LC4 Supermoto) 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 discernable. -
Page 29: Check The Rear Brake Fluid Level
min. 1 mm Checking rear brake fluid level The reservoir for the rear disc brake is located on the left-hand side of the vehicle next to the carburetor carburetor connection boot. The brake fluid level may not drop below the „MlN” marking when the vehicle is in an upright position. -
Page 30: 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... -
Page 31: Dismounting And Mounting The Rear Wheel
5 mm 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 and pull out the wheel spindle caliper support is still held. -
Page 32: 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. – S... -
Page 33: Removing The Battery
SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sunlight. -
Page 34: 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 35: 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. Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold the cooling liquid circulates only through the cylinder and the cylinder head. -
Page 36: Checking The Cooling Liquid Level
MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER – N EVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR – D UST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS... -
Page 37: Changing The Orginal Position Of The Clutch Lever
4 mm (0.16 in) below the upper edge. If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungs- fluid 75), available from your authorized KTM workshop. USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS... -
Page 38: Checking And Adjusting The Chocke Cable Play
25 mm Checking and adjusting the choke cable play * The choke lever must always have a play of approx. 4 mm (0.16 in). 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 39: Draining The Carburetor Float Chamber
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 temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). -
Page 40: 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 41: Changing Oil Filter
Let the motor run until it warms. Check the oil drain plugs and the fine screen filter to make sure they are properly sealed. 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 42: 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 43 Replace the float Replace membrane Check vacuum hose and venting hose of carburetor for correct position (no kinks) Clean or replace air filter, contact a KTM dealer Have valve clearance adjusted Check setting of the hand decompression cable Have ignition system checked...
- Page 44 Recharge the battery according to the relevant instructions. Remove seat and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer. Replace the main fuse (1) under the seat Check the sensor cable for damage and replace it if necessary.
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Page 45: 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 46: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2004 Frame Fork White Power – Up Side Down 4357 MXMA Wheel travel front/rear 275 / 290 mm (11 / 11.6 in) Rear suspension Central shock absorber (WP BAVP) with PRO-LEVER linkage to rear- swing-arm with needle bearing... -
Page 47: Tightening Torques - 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 (LC4) Screw brake caliper front (Supermoto) Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Ball joint for push rod Sprocket screws on nuts... -
Page 48: Technical Specifications - Engine
TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2004 Engine Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement Bore / Stroke Ratio Fuel unleaded premium gasoline with at least RON 95 (USA = Premium RON 91) (RON 80-94 for other ignition curve... -
Page 49: Head Word Index
Filler cap ...9 Foot brake pedal ...10 Fuel ...16 Fuel tap ...10 Fuses ...33 General information on KTM disc brakes ...25 General tips and warnings for starting the motorcycle...12 Hand brake lever ...5 Hand decompression lever ...5 Head word index ...48 Holding bars ...11... - Page 50 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...
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