KTM ENDURO 640 LC4 manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 09/2005 FOTO: MITTERBAUER 640 LC4 ENDURO 640 LC4 SUPERMOTO OWNER’S MANUAL 2006 ART. NR. 3.211.78 EN ENGLISH[...]

ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, se[...]

ENGLISH 2 INTRODUCTION » W e would like to congratulate you on your purchase of a KTM motorcycle. Y ou are now the owner of a state-of-the-art sport 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 [...]

ENGLISH 3 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. The service, care and operating instruct[...]

ENGLISH 4 INDEX » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6 Clutch lever . . . . . . . . . . . . . . . . . . . . [...]

ENGLISH 5 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. Write this number into the relevant[...]

ENGLISH 6 OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebar . The adjust- ing screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically . Hand decompression lever The h[...]

ENGLISH 7 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. The[...]

ENGLISH 8 OPERATION INSTRUMENTS » Setting options in the display KILOMETERS OR MILES. Y ou 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. T o switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx.[...]

ENGLISH 9 OPERATION INSTRUMENTS » Cooling liquid temperature display The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liq- uid 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 [...]

ENGLISH 10 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 flas[...]

ENGLISH 11 OPERATION INSTRUMENTS » 2,3,4,5 1 N N O O F F R E S F U E L N O O F F R E S F U E L N O O F F R E S F U E L OFF ON RES 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 posi- tion. Now fuel may flow to carburetor . In this positio[...]

ENGLISH 12 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 compres- sion can be adjusted. T urn the knob clockwise to increase da[...]

– WEAR SUIT ABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS AL WA YS WEAR A HELMET , BOOTS, GLOVES AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DA Y OR JUST FOR A SHOR T TRIP . THE PROTECTIVE CLOTHING SHOULD BE BRIGHTL Y COLORED SO THA T OTHER VEHICLE CAN SEE YOU AS EARL Y AS POSSIBLE. YOUR P ASSENGER WILL ALSO NEED SUIT ABLE PROT[...]

ENGLISH 14 DRIVING INSTRUCTIONS » Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK OIL LEVEL Insufficient oil results in prem[...]

ENGLISH 15 DRIVING INSTRUCTIONS » – DO NOT ST ART THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS- NESS AND DEA TH. AL W AYS PROVIDE ADEQUA TE VENTILA TION WHILE THE ENGINE IS RUNNING. – MAXIMUM PERIOD FOR CONTINUOUS ST ARTING: 5 SECONDS. W AIT A T LEAST 5 SECONDS BEFORE TRYING AGAI[...]

ENGLISH 16 DRIVING INSTRUCTIONS » – HIGH RPM RA TES WHEN THE ENGINE IS COLD HA VE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN A MODERA TE RPM RANGE FOR A FEW MILES GIV- ING IT A CHANCE TO W ARM UP . AFTER THA T NO FURTHER PRE- CAUTIONS IN THIS RESPECT NEED BE T AKEN. THE ENGINE HAS REACHED ITS OPERA TING TEMP[...]

ENGLISH 17 DRIVING INSTRUCTIONS » Stopping and parking Apply the brakes fully and put the engine into neutral. T o stop the engine, switch off the ignition. T urn the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle. – AL WA YS P ARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURF ACE. – NEVER LEA V[...]

ENGLISH 18 PERIODIC MAINTENANCE SCHEDULE » A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1. Service after 1000 km 2. Service after / every 5000 km ENGINE Change engine oil, oil filter , and fine filter z z Clean oil screens and magnet of drain plug z z Check oil lines for damage and kink-less arrangement z z Check and adjust s[...]

ENGLISH 19 PERIODIC MAINTENANCE SCHEDULE » IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least once a year every 2 years or 20000 km Perform complete fork maintenance z Perform complete suspension strut maintenance z Perform complete reversing lever maintenance z Clean and lubricate steerin[...]

ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNA TED BY AN ASTERISK * REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFES- SIONAL. FOR YOUR OWN SAFETY , AL WA YS HA VE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALL Y SERVICED BY APPROPRIA TEL Y QUALIFIED,SKILLED ST[...]

ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » Removal of seat (LC4 Supermoto) Actuate the lever [1] while lifting the back of the seat [2] . When you mount the seat, make sure the retaining brackets are fastened to the seat. Tool set (LC4 Supermoto) The tool set [3] is located under the seat. Checking and adjusting steering head bearing * Ch[...]

ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » Bleeder screws for telescopic fork After every 5 hours of use for competitive racing, slacken the breather plugs [1] a few turns in order to relieve excess pressure from the inside of the fork. T o do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding th[...]

ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 considerably more or less than 75 kg (165 lb), you should change the spring preload accordingly [A] . [...]

ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking chain tension T o 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 com- ponent. The chain should barely touch the swing arm when the upper chain part [A] is tensioned. If[...]

ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water , but never use brushes or solvents. After letting the chain dry , you can use a special X-ring chain spray (Motorex Chainlube 622). NO LU[...]

ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » General informations about KTM disc brakes BRAKE CALIPERS (LC4 Enduro): The brake calipers of this series “float“. This means that the brake calipers are not solidly attached to the caliper support. Thus, the brake pads are always in optimum contact with the brake disc. Secure the screws of t[...]

ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting of free travel at the hand brake lever (LC4 Enduro) Free travel at the hand brake lever may be readjusted by using adjusting screw [1] . In this way , the position of the point of pressure (i.e., the resist- ance you feel on the hand brake lever when the brake pads are pressed against t[...]

ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the front brake pads (LC4 Enduro) The brake pads can be inspected from below . The linings must be at least 1 mm (0.04 in) thick. A T THEIR MOST WORN POINT BRAKE P AD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE F AILURE. FOR YOUR OWN SAFETY DON’T PUT OFF[...]

ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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. IF THE BRAKE FLUID LE[...]

ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » Dismounting and mounting the front wheel (LC4 Enduro) T o 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 t[...]

ENGLISH 31 MAINTENANCE WORK ON CHASSIS AND ENGINE » Dismounting and mounting the rear wheel T o 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 [1] , remove chain tensioner [2] , hold the rear wheel and pull out the wheel spindle [3] until the rear wheel is free [...]

ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » Tires, air pressure T ire type, tire condition, and how much air pressure the tires have in them affect the way your motorcycle rides, and they must therefore be checked when- ever you’re getting ready to go anywhere on your motorcycle. IN ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFOR[...]

ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » Battery The battery is located under the seat and is maintenance-free. 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 battery: Remove screws [1] and swing ret[...]

ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » Fuses Fuse box [A] is located under the seat. See "Removing the seat" to remove and mount the seat. The fuses are numbered on the inside of the fuse box. The fuses marked "RES" are spare fuses. Replace a blown fuse only with an equivalent one. If a new fuse that has just been [...]

ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » Exchanging the brake light and tail light bulb (LC4 Supermoto) Remove seat. Disengage retaining clip [1] and take bulb out of reflector . When changing the brake-light lamp, simply pull it out of the holder . Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the [...]

ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » Exchanging the headlight lamp (LC4 Supermoto) Removing the headlight mask: Remove the left and right screws [1] and the speedometer cover . Detach the headlight mask and tilt towards the front. Replacing the headlight lamp: Pull the plug [2] off the bulb Remove the rubber cap [3] T urn the lamp b[...]

ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the cooling l[...]

ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter (LC4 Enduro) * It is very important for the engine's life expectancy to clean the air filter regularly . T o clean the air filter , remove screws [1] and the filter box cover . Detach retain- ing clip [2] and remove the air filter [3] including the filter holder [4] f[...]

ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » Exhaust system (LC4 Supermoto) * 640 Supermoto silencers are filled with glass-fiber yarn in the front and insu- lation matting in the rear for dampening. The influence of heat causes the glass-fiber yarn to become loose. This can lead to a loss of power and reduce the silencer's dampening e[...]

ENGLISH 40 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 PLA Y IN THE CHOKE CABLE, THE BORE OF THE COLD ST ARTER SYSTEM CANNOT BE COMPLETEL Y CLOSED. THIS RESUL TS IN HIGH FUEL CON- SUMPTION, AN UNEVEN RUNNING ENGINE, AND AN E[...]

ENGLISH 41 MAINTENANCE WORK ON CHASSIS AND ENGINE » Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (ROZ) is not available, you can easily activate the corresponding ignition curve. A socket connector [1] is located on a brown-black cable near the digital box. If the two conn[...]

ENGLISH 42 MAINTENANCE WORK ON CHASSIS AND ENGINE » Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard. Whereas car engines req[...]

ENGLISH 43 MAINTENANCE WORK ON CHASSIS AND ENGINE » Oil and screen filter change, bleeding of the oil system * Note: The frame breast pipe is integrated into the oil circuit for the sake of more effectively cooling the motor oil. It is thus important when changing the oil to also remove the fine screen filter , to drain the motor oil from the brea[...]

ENGLISH 44 MAINTENANCE WORK ON CHASSIS AND ENGINE » Fill 0.6 liters (0.16 US gallons) of engine oil into the can and remove the plug [1] next to the steering head. Introduce the plastic hose into the vent hole [A] , (see page 30) and fill 0.6 liters (0.16 US gallons) of engine oil into the frame’ s front tube. Remove plastic hose, start engine, [...]

ENGLISH 45 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine doesn’t crank. Operating errror Discharged battery . Defect ignition lock or emergency OFF switch T urn on the ignition, switch the gear to neutral and switch the emergency OFF switch on. Recharge the battery and investigate the causes for dis- charging; contact a KTM dealer . Check ignit[...]

ENGLISH 46 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine fails to idle Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Disassemble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Engine does not rev high Carburetor fuel leve[...]

ENGLISH 47 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY High oil consumption Buckling gear ventilation hose Engine oil level too high Engine oil too thin (viscosity) Readjust or replace ventilation hose Check engine oil level when the engine is warm; correct if necessary Use thicker engine oil; see chapter „Engine oil“ Headlight and parking light f[...]

ENGLISH 48 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 dir t can be removed before with the help of a soft water jet. NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED C[...]

ENGLISH 49 TECHNICAL SPECIFICATIONS - CHASSIS » 640 LC4 ENDURO 640 LC4 SUPERMOTO Frame Central chrome-moly-steel frame Fork WP Suspension – Up Side Down 4357 MXMA WP Suspension - Up Side Down 4860 MXMA Wheel travel front/rear 275 / 275 mm 275 / 260 mm Rear suspension Central shock absorber (WP BA VP) with PRO-LEVER linkage to rear - swing-arm wi[...]

ENGLISH 50 TECHNICAL SPECIFICATIONS - CHASSIS » TIGHTENING TORQUES - CHASSIS Collar nut front axle M16x1.5 40 Nm Collar nut rear axle M20x1.5 80 Nm Shock absorber top M10 45 Nm Shock absorber bottom M10 45 Nm Collar screws brake disk front/rear M6 (10.9) Loctite 243 + 10Nm Screw brake caliper front (Enduro) M8 Loctite 243 + 25 Nm Screw brake calip[...]

ENGLISH 51 TECHNICAL DATA – ENGINE » ENGINE 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 cc Bore / Stroke 101 / 78 mm Ratio 11.7 : 1 Fuel unleaded premium gasoline with at least RON 95 (USA = Premium RON 91) (RON 80-94 for other ignition curve V alve timing 4 valves over r[...]

ENGLISH 52 HEAD WORD INDEX » Page Accessories and payload . . . . . . . . . . . . . . . . . . . . .13 Activating the ignition curve for low-octane fuel . . . . .41 Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . .41 Adjust the throttle cable . . . . . . . . . . . . . . . . . . . . .40 Adjusting of free travel at the hand brake [...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAMM 6 0 - 5 0 0 2 M S 0 4 6 - 4 C L m a r g a i d g n i r i w 5 0 0 2 . 3 0 . 5 2 p u k c i P S P T y a l e r y r a l l i x u a t r a t s G 3 r o t a r e n e g E C U br-pi pi bu-bl bu-re gn-br gn-re ye wh gn-bl re-ye wh ye-w h bl bl-wh bl-bu or C P E M n a f g n i l o o c h c t[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAMM h c t i w s e k a r b - n g - e y l b l b h w u b d e h s u p d e h s u p n u e l b a c h c t i w s s s e n r a h e l b a c h c t i w s h c t u l c e y r b d e l l u p d e l l u p n u h c t i w s n o i t i s o p i p - r b i p e l b a c e l b a c s s e n r a h h c t i w s r [...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAMM e d o i d n r o h h c t i w s t h g i l h c t i w s p o t s / t r a t s 0 1 2 h c t i w s n r o h h c t i w s r e h s a l f h c t i w s m a e b w o l / h g i h y a l e r r e h s a l f head light flascher G bl-or bl-bu gr sidestand switch r o s n e s e r u t a r e p m e t °[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING DIAGRAMM h c t i w s e k a r b - n g - e y l b l b h w u b d e h s u p d e h s u p n u e l b a c h c t i w s s s e n r a h e l b a c h c t i w s h c t u l c e y r b d e l l u p d e l l u p n u h c t i w s n o i t i s o p i p - r b i p e l b a c e l b a c s s e n r a h h c t i w s r [...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 5 SCHALTPLAN » WIRING DIAGRAMM ENGLISH DEUTSCH IT ALIANO headlight Scheinwerfer faro parking light Standlicht luce di posizione turn indic left fr Blinker li vo lampegg ant sn turn indic left fr Blinker re vo lampegg ant dx ignition controll ON Zündungskontrolle ON spiedicontrollo ON high beam indicator[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 6 ENGLISH FRANCAIS ESP ANOL headlight phare faro parking light feu de position luz de posicion turn indic left fr clignoteur av gauche interm izquierdo delantero turn indic left fr clignoteur av droit intermitene derecho delantero ignition controll ON temion ON luces de aviso ON high beam indicator temoin[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 09/2005 FOTO: MITTERBAUER 640 LC4 ENDURO 640 LC4 SUPERMOTO BEDIENUNGSANLEITUNG 2006 ART. NR. 3.211.78 DE DEUTSCH[...]