Art.Nr. 3.210.
IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.
Introduction We would like to congratulate you on your purchase of a KTM motorcycle. ENGLISH 2 You 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.
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty.
Index Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number............................................................5 Engine number, engine type ........................................5 ENGLISH 4 OPERATION INSTRUMENTS ...............................................5 Clutch lever .................................................................5 Hand decompression lever ...........................................5 Hand brake lever ...................................
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. 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. ENGLISH Engine number, engine type 5 OPERATION INSTRUMENTS Clutch lever The clutch lever 1 is fitted on the left hand side of the handle bar.
Hand brake lever The hand brake lever 1 is mounted on the handlebar on the right and actuates the front wheel brake.The adjusting screw B is used to change the original position of the hand brake lever (see maintenance work on chassis and engine). 1 B ENGLISH Choke lever If the choke lever 2 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.
2 3 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 settings 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 additional information on the motorcycle's running condition.
1 ENGLISH 1 2 10 sec 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 longdistance 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 will switch to mph. The speed and the stored distances will be converted and displayed in miles. To return to kilometers, proceed as described above.
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. 50°C. Each additional bar represents 10°C more. When the upper bar lights up, all of the bars will start to blink and the red warning lamp 2 will light up.
Combination switch 4 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 button 4. 1 ENGLISH 1 2 3 Starter tip switch, emergency OFF tip switch, light switch Use the starter tip switch 5 to operate the electric starter.
Fuel tap A on the left side of the tank has 3 positions. OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel can flow to fuel pump. In this position the tank empties down to the fuel reserve of approx. 3,5 liters (0,9 US gallone). RES The reserve, approximately 3,5 liters (0,9 US gallone), cannot be tapped until the twist grip is turned to the RES position.
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 to reduce damping during compression.
13 ENGLISH
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation ENGLISH 14 – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read the entire manual carefully before your first drive. – Enter the chassis, engine and key numbers on page 1. – Familiarize yourself with the operating elements. – Adjust the foot brake pedal to the most comfortable positions for you.
DRIVING INSTRUCTIONS Check the following before each start When you start off, the motorcycle must be in a perfect technical 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: 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.
Starting when the engine is cold 1 2 3 4 5 6 7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the choke lever 3. Operate the starter tip switch 4 without accelerating. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Swing up the centerstand 9 Switch on the light before setting off.
Starting the engine with the kickstarter WARNING YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK THE KICKSTARTER. ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED THROTTLE GRIP INCREASE THE KICKBACK HAZARD.
Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Close fuel tap. Park on solid ground and lock the vehicle. – MOTORCYCLE – WARNING ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT.
19 ENGLISH
PERIODIC MAINTENANCE SCHEDULE ADD-ON-PARTS BRAKES CHASSIS WHEELS ENGLISH 20 CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed ti
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ENGLISH 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 Check chain tension Cl
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. 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.
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 there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged.
Changing the spring preload of the shock absorber 2 1 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 A accordingly. This is easily done. NOTE: – Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring.
Checking chain tension Support the motorcycle on the center stand or side stand, respectively. Switch transmission to neutral. Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sliding component until the upper part of the chain is tensioned (see illustr.) Now, the distance A between chain and swingarm should be 0 mm. The upper part of the chain B must be tight (see illustr.).
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).
General informations about KTM disc brakes BRAKE CALIPERS: 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 to 25 Nm (19 ft.lb). WARNING BRAKE SHOES AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHORIZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC.
Adjusting of free travel at the hand brake lever 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. min. 3 mm ! CAUTION ! AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM.
Changing the basic position of the brake pedal * A 1 The basic setting of the foot brake pedal can be changed by turning the end stop roller 1. Using the push rod 2, the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). To keep the stop roller from turning while tightening, insert a hexagon wrench in bore A.
Dismounting and mounting the front wheel 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 1 on the left fork leg. Then loosen the collar nuts 2 before loosening the clamp screws 3 on the right fork leg. Hold the front wheel and withdraw the wheel spindle 4. Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm ALLAN/IMBUS key while pulling.
Checking the shock absorption rubbers in the rear hub * LC4 models have a damped rear wheel hub. For this purpose, the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers 1 to the rear wheel. These 6 absorption rubbers wear with increasing operation time, and should be checked for wear whenever the rear wheel is dismounted. 1 For this purpose, lie the rear wheel on a work bench with the rear sprocket upwards, and put the wheel spindle in the hub.
Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. For checking, tap on each spoke with the blade of a screw driver (see illustration). A clear tone must be the result. Dull tones indicate loose spokes.
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. 1 Removing the battery: Remove screws 1 and swing retaining bracket and voltage regulator out of the way. First disconnect the negative and then the positive pole of the battery. Remove battery. When replacing, connect first the positive and then the negative pole.
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.
Exchanging the brake light and tail light bulb Remove the cap 1 on the underside of the license plate retainer. 2 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 worksteps indicated above.
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 cylinder head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the cooling liquid is also pumped through both aluminum radiators. 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.
Cleaning the air filter * It is very important for the engine's life expectancy to clean the air filter regularly. 1 Mount the air filter on the filter holder, position in the filter box (make sure to center) and fix with the retaining clip. Check whether the air filter is positioned correctly and mount the filter box cover. 3 CAUTION ! – DO ! NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAINTENANCE.
Adjusting the throttle cable * When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm (0.11-0.19 in). 3-5 mm ENGLISH 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 slide the protection cover back on. Make sure that the throttle grip will return to the idle position automatically once you let go of it.
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. 4 mm ! CAUTION ! THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON AND CYLINDER. 3 Push the choke lever all the way to the front and slide the protecting cap 1 from the adjusting part 2.
Draining of float chamber of the carburetor 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 leads to engine malfunction. Wait until the engine is cold before commencing to perform the worksteps indicated below. Close the fuel tap. Put the end of the hose 1 that leads downward behind the engine into an appropriate container.
Oil circuit 11 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 off. Then the motor oil flows through the fine screen filter 6 that removes even the finest of contaminants from the motor oil.
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 onto the hose connection piece, and you will have your filling tool. ENGLISH Fill 0.6 liters of engine oil into the can and remove the plug 1 next to the steering head.
TROUBLE SHOOTING TROUBLE CAUSE REMEDY Engine doesn’t crank. Operating errror Turn on the ignition, switch the gear to neutral and switch the emergency OFF switch on. Discharged battery. Recharge the battery and investigate the causes for discharging; contact a KTM dealer. Defect ignition lock or emergency OFF switch Check ignition lock and emergency OFF switch, contact a KTM dealer. Blown fuse safe-starting system. Replace fuse (3). Blown main fuse. Remove seat and replace the main fuse (1).
ENGLISH TROUBLE CAUSE REMEDY Engine cranks but doesn’t start. Spark plug connector or spark plug faulty Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate starter, a strong spark must be produced at the spark plug – If no spark is created exchange the spark plug. – If the new spark plug doesn't produce a spark either, disconnect the spark plug connector from the ignition cable, hold it a distance of approx. 5 mm from ground and start.
CAUSE REMEDY Engine overheats Insufficient cooling liquid Refill cooling liquid (see maintenace work), check cooling system for leaks Radiator fins are extremely dirty Clean radiator with water jet Foam forms in cooling system Replace cooling liquid, use antifreezer with brand name Bent radiator hose Shorten or replace cooling hose Thermostat defective Remove and check thermostat (opening temperature 70°C (158°F) or replace it, contact a KTM dealer Blown fan fuse Replace fuse and check if fan
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 dirt can be removed before with the help of a soft water jet. CAUTION ! ! NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC.
47 ENGLISH
TECHNICAL DATA – ENGINE 640 LC4 ADVENTURE 2003 ENGLISH 48 Type 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 Quantity of engine oil Engine oil Primary ratio Clutch Transmission Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 640 LC4 Liquid-cooled single cylinder 4-stroke engine with b
Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop screw Allan head screw freewheel hub Allan head screw oil pumps Hexagon screw camshaft gear Allan head screw cylinder head top sect. Allan head screw cylinder head top sect.
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2003 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear Rear suspension ENGLISH 50 275/300 mm (10,5/12 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres f
Other colllar nuts an chassis M16x1,5 M20x1,5 M10 M6 (10,9) M8 M12 M14x1,5 M10 M8 M14x1,5 M8 M8 M8 M4 M6 M8 M10 M6 M8 M10 40 Nm 80 Nm 45 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm 60 Nm 100 Nm 45 Nm Loctite 243 + 35 Nm 100 Nm 20 Nm 15 Nm 10 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm (30ft.lb) (59ft.lb) (33ft.lb) (7ft.lb) (19ft.lb) (44ft.lb) (74ft.lb) (33ft.lb) (25ft.lb) (74ft.lb) (15ft.lb) (11ft.lb) (7ft.lb) (3ft.lb) (7ft.lb) (19ft.lb) (33ft.lb) (11ft.lb) (22ft.lb) (37ft.
HEAD WORD INDEX ENGLISH 52 Page Page Serial number locations .........................................................5 Correct chain tension ..........................................................25 Chassis number.....................................................................5 Chain maintenance .............................................................26 Engine number, engine type .................................................5 Chain wear ............................................
1 ANHANG – APPENDICE APPENDIX – APÉNDICE
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. WARNING STATEMENT: AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. 1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases. 2) Removal or puncturing of any part of the intake system.
IMPORTANT To avoid oil spill through crankcase breather, never exceed top mark at operating temperature! KTM 640 LC4 ADVENTURE USA ANHANG – APPENDICE APPENDIX – APÉNDICE WARNING THIS SHOCK ABSORBER CONTAINS NITROGEN GAS UNDER HIGH PRESSURE. DO NOT ATTEMPT REFILLING OR REBUILDING THE SHOCK, SINCE THE SHOCK MAY BE DAMAGED.
ANHANG – APPENDICE APPENDIX – APÉNDICE 4
5 ANHANG – APPENDICE APPENDIX – APÉNDICE
5230 Mattighofen Austria Internet: www.ktm.
