Instruction/ maintenance manual of the product ENDURO 640 LC4 KTM
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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.
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.
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 .
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.
ENGLISH 4 INDEX » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS .
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.
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 .
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.
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.
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.
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.
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.
– 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.
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.
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.
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.
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.
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 f.
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 .
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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 Disass.
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 C.
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.
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 .
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.
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.
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 .
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 .
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 .
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 .
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 .
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 .
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 dela.
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.
An important point after buying a device KTM ENDURO 640 LC4 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM ENDURO 640 LC4 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM ENDURO 640 LC4 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM ENDURO 640 LC4 you will learn all the available features of the product, as well as information on its operation. The information that you get KTM ENDURO 640 LC4 will certainly help you make a decision on the purchase.
If you already are a holder of KTM ENDURO 640 LC4, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM ENDURO 640 LC4.
However, one of the most important roles played by the user manual is to help in solving problems with KTM ENDURO 640 LC4. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM ENDURO 640 LC4 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
