KTM 640 LC4 ENDURO manual

OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISA TION MANUAL DE INSTRUCCIONES ART .NR: 3.210.85 640 LC4 ENDURO 640 LC4 SUPERMOTO BEDIENUNGSANLEITUNG 2004[...]

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 ARTICULAR A TTENTION TO NOTICES THA T ARE MARKED AS FOLLOWS:  WARNIN[...]

ENGLISH 2 Introduction We 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 thor[...]

ENGLISH 3 In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality . IMPOR T ANT LIMITED W ARRANTY AND LIMITED GUARANTEE INFORMA TION The 640 LC4 Enduro model was designed to resist the usual wear and tear of normal use on the road and easy terr[...]

ENGLISH 4 Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number ................................................................5 Engine number, engine type .............................................5 OPERATION INSTRUMENTS ...............................................5 Clutch lever .........................[...]

ENGLISH 5 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 6 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 display modes can be selected with the MODE button. The indicator lamps 3 provide addit[...]

ENGLISH 7 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 1 button for approx. 10 seconds. The km/h display w[...]

ENGLISH 8 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 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 wa[...]

ENGLISH 9 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 flasher. The horn is sounded with bu[...]

ENGLISH 10 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 tapp[...]

ENGLISH 11 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 12 GENERAL TIPS AND W ARNINGS FOR ST ARTING 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. – Familiariz[...]

ENGLISH 13 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 premature wear and consequen[...]

ENGLISH 14 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 starts, push [...]

ENGLISH 15 Kickstart instructions Be sure to kick up the side stand before you start the engine to avoid any damage. 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 INJURY . Y OU MIGHT SLIDE OFF THE KICKSTA[...]

ENGLISH 16 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 17[...]

ENGLISH 18 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 19 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 20  WARNING  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. ! CAUTION ! –W HEN CLEANING T[...]

ENGLISH 21 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 22 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 . This is easily done. NOTE: – Before changin[...]

ENGLISH 23 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 A is tensioned. If not, correct the chain tension.  WARNING ?[...]

ENGLISH 24 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 Racing).  WARNING  N O LUBRICATION IS ALLOWED TO [...]

ENGLISH 25 General informations about KTM disc brakes BRAKE CALIPERS (LC4): 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 the caliper support with Loctite 243 and tighten t[...]

ENGLISH 26 Adjusting of free travel at the hand brake lever (LC4) 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 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. When[...]

ENGLISH 27 Checking the front brake pads (LC4) The brake pads can be inspected from below. The linings must be at least 1 mm (0.04 in) thick.  WARNING  A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFETY DON ’ T PUT OFF HAVING YOUR BRAKE PADS CHANGED[...]

ENGLISH 28 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 29 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 30 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 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[...]

ENGLISH 31 640 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 r e s, air pressure Tire type, tire condition, and how much [...]

ENGLISH 32 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 retaining bracket and voltage regulator out of th[...]

ENGLISH 33 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. Main fuse 1 (20 amperes) protects all power consumers against short circuits. Fuse 2 (10 Ampere) protects the following power-c[...]

ENGLISH 34 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 35 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 LIQ[...]

ENGLISH 36 Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning th[...]

ENGLISH 37 Checking and adjusting the choke cable play * The choke lever must always have a play of approx. 4 mm (0.16 in). ! CAUTION ! I F THERE IS NO PLAY IN THE CHOKE CABLE , THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED . T HIS RESULTS IN HIGH FUEL CONSUMPTION , AN UNEVEN RUNNING ENGINE , AND AN EXTREME WEAR OF PISTON AND CYLI[...]

ENGLISH 38 Draining the carburetor float chamber * Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes engine malfunction. Carry out this job with the engine being cold. Close the fuel tap. Put one end of the ho[...]

ENGLISH 39 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 40 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 (0.28 in) -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 plas[...]

ENGLISH 41 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 42 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 43 TROUBLE High oil consumption 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 No values are visible in the Tripmaster display. No speed display. CAUSE Buckling gear ventilation hose Engine oil level too high Engine oil t[...]

ENGLISH 44 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 45 TECHNICAL SPECIFICA TIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2004 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork W hite P ower – U p S ide D own 4357 MXMA W hite P ower – U p S ide D own 4860 MXMA Wheel travel front/rear 275 / 290 mm (11 / 11.6 in) 265 / 300 mm (10.6 / 12 in) Rear suspension Central shock abso[...]

ENGLISH 46 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 + 10 Nm Screw brake caliper front (LC4) M8 Loctite 243 + 25 Nm Screw brake caliper front (Supermoto) M10 Loctite 243 + 40 Nm Bearing bolt linkage ar[...]

ENGLISH 47 Engine 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm 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 Valve timing 4 valves over rocker arm and 1 overhead cams[...]

ENGLISH 48 Page Accessories and payload .....................................................12 Activating the ignition curve for low-octane fuel .................37 Adjisting of free travel at the hand brake lever ....................26 Adjust idling speed ..............................................................37 Adjusting the throttle cabl[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www .ktm.at KTM Group Partner 8/2003 FOTO: MITTERBAUER[...]