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Related Manuals for KTM Supermoto 400/640LC4-E6
Summary of Contents for KTM Supermoto 400/640LC4-E6
- Page 3 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 4 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 5: 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 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: Choke Lever
AND AN EXTREME WEAR OF PISTON AND CYLINDER WARNING THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE ’ T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE DEALER in the speedometer indicates overall mileage. The can be set to 0 by means of the setting wheel... -
Page 8: Combination Switch
S ADVICE IMMEDIATELY Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). SECONDS AIT AT LEAST SECONDS AIT AT LEAST ). N OCTANES EVER USE XTREME CAUTION SHOULD BE USED MOTORCYCLE NEAR OPEN... -
Page 9: 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 10: 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. By using the knob (COM), the degree of damping of the compression can be adjusted. -
Page 11: Driving Instructions
Arrange for the braking system to be checked by a KTM specialist garage, as complete failure of the braking system can be expected. Also check the state of the brake hoses and the thickness of the brake linings. -
Page 12: Kickstart Instructions
– 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 13: Starting Off
TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS... - Page 14 (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely.
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Page 16: 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 17 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 18: 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 SPECI- ALLY TRAINED MECHANICS. -
Page 19: 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 20: Checking Rubber Ring On The Rear 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 21: 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. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 22: Checking Of Brake Fluid Level - Front Brake
5 mm 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 23: 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 24: Dismounting And Mounting The Front Wheel
Dismounting and mounting the front wheel (400/640 LC4-E) 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... -
Page 25: Dismounting And Mounting The Rear Wheel
5 mm Dismounting and mounting the rear wheel* Park the motorcycle on the center stand. The rear wheel must not touch the ground. Loosen the collar nut and pull out the wheel spindle caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the rear sprocket and carefully take the rear wheel out of the swingarm. -
Page 26: Tires, Air Pressure
In order to ensure riding safety and optimal riding performance, only KTM- approved tires may be used. Other tires can have a negative effect on riding performance (e.g. -
Page 27: 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 28: 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 29: 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 30: Checking The Cooling Liquid Level
10 mm when engine is cold 3-5 mm 3-5 mm Checking the cooling liquid level The cooling liquid should be 10 mm (0,4 in) above the cooling elements when the engine is cold (cf. diagram). In the event of the cooling liquid being drained, always fill the system before hand, then top off while the engine is running. -
Page 31: Draining The Carburetor Float Chamber
Adjusting the throttle cable (Mikuni carburetor)* When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm. For models outfitted with the throttle twist grip depicted in the illustration, the throttle cables have to be adjusted at the carburetor. If a correction is necessary, start by removing the tank. -
Page 32: Adjusting The Choke Cable
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 minu- tes, unscrew and remove the oil dipstick, and wipe it clean with a cloth. -
Page 33: 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 34: 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 35: 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 36 Replace membrane Check vacuum hose and venting hose of carburetor for cor- rect 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 37 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 38: 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 39: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001 Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. road, driver only Air press. road with passenger Tyres rear Air press. road, driver only Air press. -
Page 40: Technical Specifications - Engine
TIGHTENING TORQUES - CHASSIS LC4-E Collar nut front axle Collar nut rear axle Shock absorber top Shock absorber bottom Collar screws brake disk front Collar screws brake disk 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... - Page 41 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator...
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Page 45: 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 Ignition lock ...5 Kickstarter...7... - Page 46 320597...