KTM Supermoto 640LC4 manual

OWNERS HANDBOOK MANUALE D’USO MANUEL D’UTILISA TION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art.Nr . 3.210.21 9/2001 640 LC4 640 LC4 SUPERMOTO[...]

ENGLISH 1 IMPOR T ANT WE STRONGL Y SUGGEST THA T YOU READ THIS MANUAL CAREFULL Y AND COMPLETEL Y BEFORE GOING ON YOUR FIRST RIDE. IT CONT AINS A GREA T DEAL OF INFORMA TION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERL Y . IN YOUR OWN INTEREST , PLEASE P A Y P AR TICULAR A TTENTION TO NOTICES THA T ARE MARKED AS FOLLOWS:  WARNI[...]

ENGLISH 2 Introduction We would like to congratulate you on your purchase of a KTM motor cycle. Y ou 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 . Before you go for your first ride, be sure to read this manual carefully and th[...]

ENGLISH 3 Page SERIAL NUMBER LOCATIONS .............................................4 Chassis number ................................................................4 Engine number, engine type .............................................4 OPERATION INSTRUMENTS ...............................................4 Clutch lever .........................[...]

ENGLISH 4 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. Write this number into the relevant area on page 1. Clutch le[...]

ENGLISH 5 Choke lever If the choke lever 1 is pulled backwards, a bore will be opened in the carburetor through which the engine may draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. If the choke lever is pushed forward up to the stop, the bore will be closed again. In this position the choke cable must [...]

ENGLISH 6 Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch 2 returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button 3 . The light signal (high beam) is actuated with bu[...]

ENGLISH 7 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. 2.5 liters. RES The reserve, approximately 2.5 liters, cannot be tappe[...]

ENGLISH 8 4 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. Turn the knob clockwise to increase damping, turn it counterclockwise[...]

ENGLISH 9 – Adjust the hand brake lever and the foot brake pedal to the most comfortable positions for you. – Get used to handling the motorcycle on an empty car park, before starting on a longer drive. Also try to drive as slowly as possible and in standing position, to improve your feeling for the vehicle. – Do not drive along off-road trac[...]

ENGLISH 10 1 2 4 5 3 6 Starting when the engine is cold 1 Open the fuel tap 1 2 Switch on ignition (turn ignition key 2 into position ). 3 Switch on emergency OFF switch 3 . 4 Switch transmission to idle (green indicator lamp N 4 lights up). 5 Operate cold starting device (choke) 5 . 6 Do not accelerate; operate starter button 6 . 7 If the engine s[...]

ENGLISH 11 What to do when the engine is „flooded” The throttle must be fully opened when starting. If necessary change spark-plug. Kickstart instructions Start as described above, then push the kickstarter hard ALL THE WAY.  WARNING  –W HEN STARTING THE ENGINE , MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID[...]

ENGLISH 12 Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Turn the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle.  WARNING  – ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE . –N EVER LEAVE YOUR MOTORCY[...]

ENGLISH 13[...]

ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE 1. Service after 1000 km 2. Service after 5000 km, then every 5000 km or once a year IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM . M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBST[...]

ENGLISH 15 VIT AL 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 ● Remo[...]

ENGLISH 16  WARNING  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. ! CAUTION ! –W HEN [...]

ENGLISH 17 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 screws 1 of the top triple clamp and turn steering stem bolt clockwise 2 until [...]

ENGLISH 18 Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibration damper. This ring gets pressed together with time and loses its shock absorbing quality. Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0[...]

ENGLISH 19 Chain wear In order to check the chain wear, regard the following instructions: Shift the gear into idling and pull the upper chain strand with approx. 10-15 kilogramm (33 lb) upwards (see figure). Now one can measure a space of 18 chain reels at the lower chain strand. The chain should be replaced at the latest when a space of 272 mm (1[...]

ENGLISH 20 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.  WARNING  I F THE BRAKE FLUID LEVEL DROPS B[...]

ENGLISH 21 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.  WARNING  I F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIM[...]

ENGLISH 22 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 2 on the left fork leg. Then loosen the collar nuts 1 before loosening the clamp screws 2 on the right fork leg. Hold the front wheel and withdraw the[...]

ENGLISH 23 Dismounting and mounting the rear wheel (LC4) Park the motorcycle on the center stand. The rear wheel must not touch the ground. Loosen the collar nut 1 , remove chain tensioner 2 , hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held. Push the rear wheel as far for[...]

ENGLISH 24 640 LC4 front rear Road, driver only 1,8 bar (26psi) 2,0 bar (29psi) Road, with passenger 2,0 bar (29 psi) 2,2 bar (31psi) 640 LC4 Supermoto front rear Road, driver only 2,0 bar (29psi) 2,2 bar (31psi) Road, with passenger 2,2 bar (31psi) 2,4 bar (34psi) TIRES - AIR PRESSURE Ti res, air pressure Tire type, tire condition, and how much ai[...]

ENGLISH 25 Battery The battery is mounted under the seat (remove the seat, see page 16). The battery has a closed system and therefore requires no maintenance. 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 batter[...]

ENGLISH 26 Main fuse Located near the battery under the seat, the main fuse 1 protects all power consumers. 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. ! CAUTION ! U NDER NO CIRCUMSTANCES IS [...]

ENGLISH 27 Exchanging the brake light and tail light bulb Remove the cap 1 on the underside of the license plate retainer. Turn the lamp socket 2 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. To mount the lamp reverse the[...]

ENGLISH 28 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.  WARNING  I FP OSSIBLE , ALWAYS CHECK LEVEL OF COOLING LIQUID[...]

ENGLISH 29 Adjusting the throttle cable * When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm. If a correction is necessary, start by removing the tank. Slide back the protection cover 1 . To set the backlash, loosen the counter nut 2 and turn the adjusting screw 3 accordingly. Then, fasten the counter nut and sli[...]

ENGLISH 30 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. Push the choke lever all the way to the front and slide the protecting cap 1 from the adjusting part 2 . Loosen the lock nut 3 and correct the play by turning the adjusting part. Tighten loc[...]

ENGLISH 31 Oil circuit The oil pump 1 pumps the motor oil past the bypass valve 2 and through the oil filter 3 . Beyond the oil filter, one of the oil lines forks off to a jet 4 that injects motor oil to the piston pin bearing and the piston head. The second oil line leads the main oil flow to the frame breast pipe 5 where the motor oil is cooled o[...]

ENGLISH 32 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. Slip the plastic hose on[...]

ENGLISH 33 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case[...]

ENGLISH 34 TROUBLE Engine fails to idle Engine does not rev high Engine will not reach full power Engine overheats CAUSE Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Carburetor fuel level too high because Float needle is dirty or worn out Float leaks The cold starting syste[...]

ENGLISH 35 TROUBLE High oil consumption All switched on lamps blown out Headlight and parking light fail Flasher lights, brake light, fan and horn fail The NEUTRAL lamp is not on even though the gear is in NEUTRAL The battery is discharged CAUSE Buckling gear ventilation hose Engine oil level too high Engine oil too thin (viscosity) Voltage regulat[...]

ENGLISH 36 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 ! N EVER CLEAN YOUR MOTORCYCLE WITH A HIGH - PRESSURED[...]

ENGLISH 37 TECHNICAL SPECIFICA TIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork W hite P ower – U p S ide D own 4357 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with need[...]

ENGLISH 38 TECHNICAL DA T A – ENGINE 640 LC4, 640 LC4 SUPERMOTO 2002 Collar nut front axle M16x1,5 40 Nm (30ft.lb) Collar nut rear axle M20x1 ,5 80 Nm (59ft.lb) Shock absorber top M10 45 Nm (33ft.lb) Shock absorber bottom M10 45 Nm (33ft.lb) Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10 Nm (7ft.lb) Screw brake caliper front M8 Lo[...]

ENGLISH 39 Engine 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 624,6 ccm Bore / Stroke 101 / 78 mm Ratio 11 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft 249/1 Val[...]

ENGLISH 40 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in adition to notifying KTM Sportmotorcycle USA, Inc. If NHTSA receives similar complaints, it may open an investigation,[...]

ENGLISH 41 WARNING THIS SHOCK ABSORBER CONTAINS NITROGEN GAS UNDER HIGH PRES- SURE. DO NOT ATTEMPT REFILLING OR REBUILDING THE SHOCK, SINCE THE SHOCK MAY BE DAMAGED. REFER TO THE OWNERS MANUAL KTM 640 LC4, 640 LC4 Supermoto 2002 THIS KTM EXHAUST SYSTEM 583.05.083.200 MEETS EPA NOISE EMISSION REQUIREMENTS OF 80 dBA FOR MODEL SPECIFIC CODE KTM 584062[...]

ENGLISH 42 KTM 640 LC4, 640 LC4 Supermoto 2002[...]

ENGLISH 43 page Adjisting of free travel at the hand brake lever ....................19 Adjusting idling speed .........................................................28 Adjusting the choke cable ...................................................30 Adjusting the clutch cable ...................................................29 Adjusting the thro[...]

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KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www .ktm.at 321021[...]