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Table of Contents
Related Manuals for KTM Supermoto 640LC4
Summary of Contents for KTM Supermoto 640LC4
- 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 series numbers of your motorcycle in the boxes below Chassis number Engine number Stamp of dealer...
- Page 3 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
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Page 4: Table Of Contents
Checking chain tension...18 Correct chain tension...18 Chain maintenance...18 Chain wear...19 General information on KTM disc brakes ...19 Adjisting of free travel at the hand brake lever ...19 Checking of brake fluid level - front brake...20 Refilling the front brake fluid reservoir...20 Checking the front brake pads...20... -
Page 5: 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 6: Choke Lever
F THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE ’ BRAKE SYSTEM T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A DEALER Speedometer, indicator lamps The mileage indicator... -
Page 7: Combination Switch
OCTANES OCTANES BECAUSE IT MAY DAMAGE THE ENGINE WARNING XTREME CAUTION SHOULD BE USED GASOLINE REFUEL MOTORCYCLE LWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING F GASOLINE IS SWALLOWED OR SPLASHED IN ’ S ADVICE IMMEDIATELY AIT AT LEAST ). N... -
Page 8: 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 9: 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 compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression. -
Page 10: Driving Instructions
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE Instructions for initial operation – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read the entire manual carefully before your first drive. - Page 11 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 –...
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Page 12: Kickstart Instructions
ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO ENGINE DAMAGE – 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... -
Page 13: Stopping And Parking
(see illustration). Make sure that the ground is solid and that your motorcycle is standing securely. CAUTION HE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY... -
Page 15: 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 16 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC 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 Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary...
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Page 17: 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 18: Checking And Adjusting Steering Head Bearing
At least once a year, the steering head bearings should be greased. Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only, weighing approximately 75 kg (165 lb). If you want to take a passenger with you, of if you weigh... -
Page 19: Checking Rubber Ring On The Rear 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. OT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK... -
Page 20: Chain Wear
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 21: Checking Of Brake Fluid Level - Front Brake
min. 1 mm 3-5mm Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the brake fluid level should not go below middle of the glass. -
Page 22: 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 23: 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 nuts before loosening the clamp screws Hold the front wheel and withdraw the wheel spindle Note: The wheel spindle can be withdrawn more easily by turning it mode- rately with a 6 mm ALLAN/IMBUS key while pulling. -
Page 24: Dismounting And Mounting The Rear Wheel
80 Nm (60 ft.lb), push the rear wheel forwards so that the chain tensioners lie on the tension screws. Dismounting and mounting the rear wheel (LC4 SUPERMOTO)* To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Remove rear screw... -
Page 25: 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 26: Battery
DESTROY THE RECTIFIER REGULATOR 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 sun radiation. Charging the battery Remove the battery and check the charging level. -
Page 27: Main Fuse
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. The fuse capacity is 20 Ampere. -
Page 28: Exchanging The Brake Light And Tail Light Bulb
Air blowing in through the radiators cools the cooling liquid. The slower the speed of the motorcycle, the less the cooling liquid is cooled down. Dirty radiator fins also reduce the cooling efficiency. If little or no air blows through the radiators, for example when riding through slow traffic or waiting at traffic lights, the coolant temperature will rise. -
Page 29: Checking The Cooling Liquid Level
Check whether the air filter is positioned correctly and mount the filter box cover. – D O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE . KTM THE FOAM MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER –... -
Page 30: Adjusting The Throttle Cable
Adjusting the throttle cable * When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm. 3-5 mm If a correction is necessary, start by removing the tank. Slide back the protection cover . To set the backlash, loosen the counter nut and turn the adjusting screw accordingly. -
Page 31: Checking And Adjusting The Chocke Cable Play
Allow the engine to run at idle speed for about 4 minutes. Turn off the engine and place the motorcycle on a flat, level surface (center stand). Wait 5 minutes, unscrew and remove the oil dipstick, and wipe it clean with a cloth. -
Page 32: 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 33: Changing Oil Filter
Check the level of the motor oil. Place the motorcycle on a horizontal surface (main stand) and wait for 5 minutes. Remove the dip stick and wipe it with a piece of cloth SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN. -
Page 34: 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 35 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 36 Connect cable to ground; neutral switch must be replaced if indicator lamp lights up. Check connections and cables. 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.
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Page 37: 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 38: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002 Frame Fork Wheel travel front/rear Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Front brake disc Rear brake Tyres front Air press. -
Page 39: T Echnical Specifications - Engine
Collar nut front axle Collar nut rear axle Shock absorber top Shock absorber bottom Collar screws brake disk front/rear Screw brake caliper front Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Ball joint for push rod Sprocket screws on nuts Collar nut swingarm bolt Clamping screws top triple clamp (USD 43) -
Page 40: Engine Oil
Engine Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement Bore / Stroke Ratio Fuel Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing... -
Page 44: Head Word Index
Filler cap ...6 Foot brake pedal ...7 Fuel ...6 Fuel tap ...7 Fuses for individual power-consuming units ...26 General information on KTM disc brakes ...19 Hand brake lever ...5 Hand decompression lever ...4 Head word index ...43 Holding bars ...8 Ignition lock ...5... - Page 46 321021...
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