KTM LC4 640 Enduro, LC4 640 Supermoto motorcycle OWNER'S MANUAL

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KTM Group Partner

KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

OWNER’S MANUAL

2006

640 LC4 ENDURO

640 LC4 SUPERMOTO

ART. NR. 3.211.78 EN

IMPORTANT

Please 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 attention to notices that are marked as follows:

– IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB!

– IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR-

CYCLE’S TRAFFIC SAFETY!

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

Stamp of dealer

COMSUMER INFORMATION FOR AUSTRALIA ONLY

Tampering with noise control system prohibited

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

INTRODUCTION

We would like to congratulate you on your purchase of a KTM motorcycle.

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.

Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on

motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your

KTM should be performed by a qualified KTM dealer.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full.

It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others.

We wish you a lot of fun when driving !

KTM-SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: 1 spare parts manual chassis & engine

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 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.

The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule.

The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached.

No warranty will be assumed if the bike is used in races or competitions.

In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

INDEX

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ignition lock with 3 switch positions . . . . . . . . . . . . . .6

Multi-functional digital speedometer . . . . . . . . . . . . .7

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Setting options in the display . . . . . . . . . . . . . . . . . . .8

Cooling liquid temperature display . . . . . . . . . . . . . . .8

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .10

Starter tip switch, emergency OFF tip switch, light switch .10

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Compression damping of fork . . . . . . . . . . . . . . . . .12

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .12

Compression damping of shock absorber . . . . . . . . . .12

Rebound damping of shock absorber . . . . . . . . . . . . .12

Holding bars (LC4 Enduro) . . . . . . . . . . . . . . . . . . . .12

Grip (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . .12

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Instructions for initial operation . . . . . . . . . . . . . . . .13

Running in the LC4 models . . . . . . . . . . . . . . . . . . .13

Accessories and payload . . . . . . . . . . . . . . . . . . . . .13

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .14

Check the following before each start . . . . . . . . . . . .14

Starting when the engine is cold . . . . . . . . . . . . . . . .14

Starting when the engine is warm or hot . . . . . . . . . .15

What to do when the engine is „flooded” . . . . . . . . . .15

Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . .16

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .18

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .20

Tool set (LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . .20

Removing the seat (LC4 Enduro) . . . . . . . . . . . . . . . .20

Removal of seat (LC4 Supermoto) . . . . . . . . . . . . . . .21

Tool set (LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . .21

Checking and adjusting steering head bearing . . . . . .21

Bleeder screws for telescopic fork . . . . . . . . . . . . . . .22

Cleaning the dust sleeves of the telescopic fork . . . . .22

Changing the spring preload of the shock absorber . . .23

Lubricating the shock absorber linkage . . . . . . . . . . .23

Checking rubber ring on the WP rear shock absorber . .23

Checking chain tension . . . . . . . . . . . . . . . . . . . . . .24

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .24

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .25

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

General informations about KTM disc brakes . . . . . . .26

Page

Adjusting of free travel at the hand brake lever (LC4 Enduro) .27

Changing the basic position of the handbrake lever

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Checking of brake fluid level - front brake . . . . . . . . .27

Refilling the front brake fluid reservoir . . . . . . . . . . .27

Checking the front brake pads (LC4 Enduro) . . . . . . .28

Checking the front brake pads (LC4 Supermoto) . . . . .28

Changing the basic position of the foot brake pedal . .28

Checking rear brake fluid level . . . . . . . . . . . . . . . . .29

Checking the rear brake pads . . . . . . . . . . . . . . . . . .29

Dismounting and mounting the front wheel (LC4 Enduro) .30

Dismounting and mounting the front wheel

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Dismounting and mounting the rear wheel . . . . . . . . .31

Checking the shock absorption rubbers in the rear hub .31

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .32

Changing the wheel size . . . . . . . . . . . . . . . . . . . . . .32

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .33

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Exchanging the brake light and tail light bulb

(LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Exchanging the brake light and tail light bulb (LC4

Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Exchanging the headlight lamp (LC4 Enduro) . . . . . . .35

Replacing the parking-light bulb (LC4 Enduro) . . . . . .35

Exchanging the headlight lamp (LC4 Supermoto) . . . .36

Replacing the parking-light bulb (LC4 Supermoto) . . .36

Adjusting the headlight range (LC4 Supermoto) . . . . .36

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Checking the cooling liquid level . . . . . . . . . . . . . . .37

Cleaning the air filter (LC4 Enduro) . . . . . . . . . . . . . .38

Cleaning of air filter (LC4 Supermoto) . . . . . . . . . . . .38

Exhaust system (LC4 Supermoto) . . . . . . . . . . . . . . .39

Changing the original position of the clutch lever . . . .39

Checking the oil level of the hydraulic clutch . . . . . . .39

Checking and adjusting the choke cable play . . . . . . .40

Checking the adjustment of the hand decompression cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Adjust the throttle cable . . . . . . . . . . . . . . . . . . . . .40

Activating the ignition curve for low-octane fuel . . . . .41

Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . .41

Draining the carburetor float chamber . . . . . . . . . . . .41

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Checking the engine oil level . . . . . . . . . . . . . . . . . .42

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Oil and screen filter change, bleeding of the oil system .43

Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .44

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .45

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .48

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Re-initiation after time of storage . . . . . . . . . . . . . . .48

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . .49

TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . .51

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .52

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix

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 area on page 1.

OPERATION INSTRUMENTS

Clutch lever

The clutch lever [1] is located on the left side of the handlebar. The adjusting 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 hand decompression lever [2] is only used in two special cases: a) When the engine stalled.

It is possible that the starter motor is not able to crank the engine on the next attempt. This is due to the fact that the automatic decompressor doesn’t work properly. If this happens, pull the manual decompression lever and start again. Afterwards normal starting will be possible.

b) When you want to push the motorcycle.

While pushing, pull the hand decompression lever to make it easier to get the engine going.

Hand brake lever

The hand brake lever [3] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see "Maintenance").

Choke lever

If the choke lever

[4] 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 have a play of approx. 4 mm.

Ignition lock with 3 switch positions

Switch positions of ignition lock

[5]:

= Ignition off, (engine can't be started)

= Ignition on, (engine can be started)

= Ignition off, handlebar blocked

To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar to the left, then turn the ignition key to the left.

The ignition key can be withdrawn in position and .

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 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.

Display

TEST

When you switch on the ignition, all of the display elements will light up for

1 second for the function test.

TEST

WS

CLOCK

ODO

TRIP 1

TRIP 2

WS (wheel size)

The display will change and show the diameter of the front wheel in inches for 1 second (WS = wheel size).

Then the CLOCK mode will be displayed, or the mode that was active when the ignition was switched off.

CLOCK

You will recognize the OK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock.

To switch to the next display mode, press the MODE button.

ODO

The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode.

To switch to the next display mode, press the MODE button.

TRIP 1

The TRIP 1 mode shows the speed, the temperature of the cooling liquid and the trip odometer 1.

To switch to the next display mode, press the MODE button.

TRIP 2

The TRIP 2 mode shows the speed, the temperature of the cooling liquid and the trip odometer 2.

To return to the CLOCK mode, press the MODE button.

OPERATION INSTRUMENTS

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 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 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.

CLOCK

Switch on the ignition and change to the CLOCK mode.

Simultaneously press MODE [1] and SET [2]. The numbers on the clock will start to blink. Use the MODE button to set the hours and the SET button to set the minutes.

The press the MODE and SET buttons simultaneously.

NOTE: 0:00 will be displayed if the clock is not supplied with electricity. This can be caused by a defective fuse or a fault in the board electric system (see

Troubleshooting).

TRIP 1

The trip meter 1 runs continuously and counts up to 999.9. It can be used to measure the length of a certain route on a trip or the distance between two refueling stops.

To return the trip meter 1 to zero, switch on the ignition, change to the

TRIP 1 mode and press the SET button.

RESETTING TRIP 2

The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook.

To return the trip meter 2 to zero, switch on the ignition, change to the TRIP

2 mode and press the SET button.

NOTE: A Tripmaster switch (Part no. 582.14.069.044) is available as an accessory and enhances the trip meter 2 functions. You can correct the displayed route by increasing or decreasing in increments of 0.1. For example, if you have taken the wrong road when driving according to a roadbook, you can easily correct the display to correspond to the roadbook again. It can also be used to change the display modes. The switch is mounted on the handlebars so that you can keep your hands on the handlebars.

OPERATION INSTRUMENTS

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

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 warning lamp [2] will light up.

POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED

WARNING LIGHT FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP:

– DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEM-

PERATURES

– NOT ENOUGH COOLING LIQUID IN THE SYSTEM

– THE VENTILATOR ON THE RADIATOR IS NOT RUNNING

– IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY

Indicator lamps

The green indicator lamp will blink in the blinker rhythm when the blinker is switched on.

NOTE:

The indicator lamp will blink slower when a blinker is broken.

The green indicator lamp will light up when the gearbox is in an idling position.

The blue indicator lamp will light up when the high beams are switched on.

The red warning lamp will start to blink when the cooling liquid reaches

120°C (248°F).

This warning light has no function.

This indicator lamp has no function.

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 flasher.

The horn is sounded with button [4].

Starter tip switch, emergency OFF tip switch, light switch

The emergency off switch [5] is provided for emergency situations and should not be used to switch off the engine.

The engine is ready for operation in position (ignition circuit and starter circuit are switched on).

The engine cannot be started in position (ignition circuit and starter circuit are interrupted).

The light switch [6] has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch [7] to operate the electric starter.

Filler cap

The filler cap [8] can be locked and is provided with a fuel evaporation control system.

To open the cap insert the ignition key, turn it 90° counterclockwise, then lift off the filler cap.

To close the tank insert the filler cap, turn the ignition key 90° clockwise and take out the key.

OPERATION INSTRUMENTS

Fuel tap

OFF In this position the fuel tap is closed. No fuel may flow to the carburetor.

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 tapped until the twist grip is turned to the RES position. Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time, too.

OFF

R E S

ON

R E S

RES

R E S

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

N

2,3,4,5

1

Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.

Foot brake pedal

The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

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 compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

BASIC SETTING:

– turn rotary knob clockwise as far as it will go

– turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork

WP 05187B02 ........................20 clicks (640 LC4 Enduro)

WP 14187B07 ........................23 clicks (640 LC4 Supermoto)

Rebound damping of fork

The rebound damping is to be set at the upper end of the fork tubes. It only regulates the degree of damping during rebounding.

By using the knob [2] (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

BASIC SETTING:

– turn rotary knob clockwise as far as it will go

– turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork

WP 05187B02 ........................12 clicks (640 LC4 Enduro)

WP 14187B07 ........................19 clicks (640 LC4 Supermoto)

Compression damping of shock absorber

With the knob [3] the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during compression.

BASIC SETTING:

WP 01187B03 ........................position 3 (640 LC4 Enduro)

WP 01187B02 ........................position 4 (640 LC4 Supermoto)

Rebound damping of shock absorber

With the setting wheel

[4] the degree of damping of the rebound can be adjusted to 11 positions. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding.

BASIC SETTING:

WP 01187B03 ........................position 7 (640 LC4 Enduro)

WP 01187B02 ........................position 8 (640 LC4 Supermoto)

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COM-

PRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO

DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE

RESULT.

Holding bars (LC4 Enduro)

The passenger can hold on to the holding bars on the rear end of the vehicle.

Grip (LC4 Supermoto)

The passenger grip is located in the center of the seat.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for initial operation

– Make sure the work for the „pre-delivery inspection“ was performed by your authorized KTM workshop. The DELIVERY

CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

– Read these operating instructions carefully before your first ride.

– Enter the chassis, engine and key numbers on page 1.

– Familiarize yourself with the operating elements.

– Adjust the hand brake lever and foot brake lever to your most comfortable position.

– Get used to handling the motorcycle on an empty parking lot or open space, 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 tracks which go beyond your abitily and experience.

– Hold the handlebars with both hands and leave your feet on the foot rests while driving.

– Remove your foot from the foot brake lever when you are not braking. If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated.

– Do not make any alterations to the motorcycle and always use

ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle.

– Motorcycles are sensitive to changes in the weight distribution. Read the section on "Accessories and payload“ when carrying luggage.

– Pay attention to running-in procedure.

Running in the LC4 models

Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding against one another for quite some time. Therefore, every engine needs to be broken in. For this reason, during its first 1000 kilometers (620 miles) the engine must not be revved up to its performance limits. The engine speed of 4800 r.p.m. must not be exceeded during the first 1000 kilometers (620 miles). During this break-in time, you should ride your motorcycle in different conditions

(roads, easy off-road terrain). The following table shows you the maximum velocity values in the different gears at 4800 r.p.m.

as based on the rear wheel transmission ratio of your motorcycle.

gear

1st

4th

5th ratio

2nd

3rd

LC4 Enduro LC4 Supermoto

16:42 t 17:42 t

35 km/h 35 km/h

50 km/h

70 km/h

90 km/h

100 km/h

55 km/h

75 km/h

95 km/h

105 km/h

NOTE: During the stage of running the engine in, that is the first

1000 KM (620 miles), the engine oil used should be of a mineral oil formula. This also applies if the engine has been repaired.

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE.

CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES

AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR

JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD

BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU

AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED

SUITABLE PROTECTIVE CLOTHING.

– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIV-

ERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

– THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY

WITH TIRES THAT HAVE THE SAME PROFILE TYPE.

– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT

THEY MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PUR-

POSE, RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED

DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TILTING

THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE

PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL

GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN.

– DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS

OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY

OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED

WHEN THE TIRES ARE WARM.

– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND

TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZ-

ARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE.

– CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS

AND YOUR DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRI-

ALS.

– RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR

GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY

SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR

OR GOGGLES, THE OPERATOR WILL BE BLINDED.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING.

Accessories and payload

Accessory parts and baggage can significantly decrease a motorcycle's driving stability. Please observe the following warnings.

– ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM.

FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING

PROPERTIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC.

CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR

THE VEHICLES DRIVING PROPERTIES.

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOU HAVE

MOUNTED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY

PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE'S HAN-

DLING, ESPECIALLY IN THE MAXIMUM SPEED RANGE.

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOUR MOTOR-

CYCLE IS LOADED WITH CASES OR OTHER BAGGAGE. THEY WILL

IMPAIR THE MOTORCYCLE'S HANDLING AT HIGHER SPEEDS AND

CAN EASILY CAUSE IT TO GO OUT OF CONTROL

– IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFAC-

TURER'S RECOMMENDED MAXIMUM PAYLOAD.

– FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTOR-

CYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND

REAR WHEELS AND ON THE LEFT AND RIGHT.

– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND;

LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.

– A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING

AND CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT

YOUR DRIVING SPEED ACCORDINGLY.

– NEVER EXCEED THE MAXIMUM PERMISSIBLE LADEN WEIGHT

AND THE AXLE WEIGHTS. THE MAXIMUM PERMISSIBLE LADEN

WEIGHT IS MADE UP OF THE FOLLOWING COMPONENTS:

– MOTORCYCLE READY FOR OPERATION AND TANK FULL

– LUGGAGE

– DRIVER WITH PROTECTIVE CLOTHING AND HELMET.

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 premature wear and consequently to engine damage.

2 FUEL

Check that there is sufficient fuel in the tank.

3 CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear of chain and chain wheels.

4 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced.

The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

5 BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn. If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads.

Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.

Also check the state of the brake hose and the thickness of the brake linings.

Check free travel at hand brake lever and foot brake lever.

6 CABLES

Check correct setting and smooth operation of all control cables.

FLUID

Check the level of cooling fluid when the engine is cold.

SYSTEM

Check correct operation of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

10 REAR MIRROR

Sit on the motorcycle and check the adjustment of the rear mirror.

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 the choke lever back a little bit, as soon as the engine runs unevenly.

8 Take the motorcycle off of the main stand or side stand.

– TO AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE

KICKSTARTER.

DRIVING INSTRUCTIONS

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM.

EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS-

NESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE

ENGINE IS RUNNING.

– MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN.

– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE

WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE

WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE

ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD

UNTIL THE ENGINE IS WARM.

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER

TIP SWITCH:

– the transmission is switched to idle

– Check if the emergency OFF switch is on

– Check if the ignition is on

– the headlight is on.

– If this is not the case, the battery is discharged

– If the lights are on, proceed as described in the „Trouble-shooting“ section or contact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE

STARTER TIP SWITCH:

– Check if the fuel tap is open

– Check if the choke lever has been operated

– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank

– if sufficient fuel is in the tank, proceed as described in the „Troubleshooting“ section or contact a KTM dealer.

NOTE:

If you have trouble starting the motorcycle, this could be due to old fuel in the float chamber. The easily inflammable components of the new fuels evaporate during longer periods of standstill.When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel.

NOTE:

This motorcycle is equipped with a safety starter system. The engine can only be started when the transmission is switched to idle or the clutch lever is pulled, respectively.

Motorcycles with side stands are also equipped with a safety starting system.

If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop.

Starting when the engine is warm or hot

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 Do not accelerate; operate starter button

[6].

6 Take the motorcycle off of the main stand or side stand.

What to do when the engine is „flooded”

The throttle must be fully opened when starting. If necessary change spark-plug.

DRIVING INSTRUCTIONS

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.

– WHEN STARTING THE ENGINE, MAKE SURE THAT YOU ALWAYS WEAR

STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY. YOU

MIGHT SLIDE OFF THE KICKSTARTER, OR THE ENGINE MAY CAUSE

THE KICKSTARTER TO RECOIL, THEREBY CAUSING INJURIES TO

FOOT AND LEG.

– ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND,

WHILE DOING SO, NEVER OPEN THE THROTTLE. KICKSTARTING

WITH INSUFFICIENT MOMENTUM AND AN OPENED THROTTLE

LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL.

BEFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE

SIDE STAND.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time.

BEFORE YOU START OFF, CHECK THAT THE MAIN STAND HAS BEEN

SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE

MOTORCYCLE CAN GO OUT OF CONTROL.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear.

Depending on the conditions (traffic, road gradient, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever and shift to the next higher gear. Let clutch lever go again and open throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm.

When you reach full speed through turning the throttle grip all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Never open the throttle wider than the engine can handle. Excessive turning of the throttle grip will increase full consumption.

By shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear.

Let clutch lever go slowely and open throttle or shift down again.

If, for example, the engine stalls at an intersection, simply pull the clutch lever and start. You do not need to shift into the neutral position.

– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV-

ING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRE-

CAUTIONS IN THIS RESPECT NEED BE TAKEN. THE ENGINE HAS

REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADI-

ATORS BECOME WARM.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN

TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING

THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT

THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

– LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH

CAN LEAD TO ENGINE DAMAGE.

– NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER.

OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE

INCREASED WEAR.

– THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT

TEMPERATURE HAS REACHED 120°C.

POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE:

-LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR

TEMPERATURES

-LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT

-FAN AT LEFT RADIATOR IS NOT RUNNING

-IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOC-

ITIES

PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY,

SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE.

- CAUTION SCALDING HAZARD! - AND CHECK THE COOLING LIQ-

UID LEVEL.

DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE

COLING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS

AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REME-

DIED.

– IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK

THAT THE ENGINE FASTENING BOLTS ARE TIGHT.

– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMME-

DIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED

KTM DEALER.

Braking

Close throttle and apply the hand and foot brakes at the same time.

Carefully apply the brakes on sandy, wet or slippery surfaces.

Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed.

Always finish braking before you enter a curve.

When driving downhill, use the braking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to brake so much and the brakes will not overheat.

– AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS

AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EAS-

ILY LOSE CONTROL OVER YOUR MOTORCYCLE.

– WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION

LOCK TO POSITIONS AND .

– DO NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING. YOUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY

CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE.

– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.

– IN THE RAIN, OR AFTER THE MOTORCYCLE HAS BEEN WASHED,

BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS.

FIRST, THE BRAKES MUST BE BRAKED DRY.

– ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE

DELAYED AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN.

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE

CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS

GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES,

THE ENTIRE BRAKING SYSTEM CAN FAIL.

– DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS

AND BRAKE DISCS.

– IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE

PEDAL FEELS “SPONGY” (TOO MUCH PLAY), THIS IS AN INDICA-

TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T

RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE

BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

DRIVING INSTRUCTIONS

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.

– ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE

ENGINE IS RUNNING.

– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-

NING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS,

AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF

THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK

IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZ-

ARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE

ENGINE IS RUNNING.

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CAR-

BURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE.

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE

SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.

35 mm

INFORMATION ABOUT THE SIDE STAND:

Use your foot to push the side stand forward as far as possible, and lean your motorcycle to the side. Make sure that your motorcycle is standing safely on solid ground. Just in case, you can also put in a gear.

– PARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD

GROUND, LEVEL SURFACE) AND CAN’T TIP OVER.

– THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE

ONLY. IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDI-

TIONAL LOAD ONTO THE SIDE STAND, YOU MAY CAUSE DAMAGE TO THE SIDE

STAND OR THE FRAME, AND YOUR MOTORBIKE MAY FALL OVER.

NOTE REGARDING THE CENTER STAND: (is available as an accessory)

We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible: a) press main stand to ground using foot b) swing out kickstarter and pull motorcycle backwards at an angle as illustrated (see illustration).

Make sure that the ground is solid and that your motorcycle is standing securely.

THE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE

ONLY. BY SITTING ON THE MOTORCYCLE, YOU WILL PUT ADDITIONAL WEIGHT ON

THE CENTER STAND, POSSIBLY CAUSING THE CENTER STAND OR FRAME TO BE

DAMAGED OR THE MOTORCYCLE TO FALL DOWN.

Fuel

In the condition at delivery, the LC4 engine requires unleaded premium-grade fuel with at least 95 octane (ROZ).

If using lower octane fuel, it is easy to change over to the pre-programmed ignition curve for 80 - 94 octane (ROZ) (see activating the ignition curve for low-octane fuel).

USE UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER

OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE

DAMAGE WILL OCCUR.

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD

BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR

OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE

BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR

EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASO-

LINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR’S ADVICE IMME-

DIATELY.

Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).

PERIODIC MAINTENANCE SCHEDULE

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 tight

Check carburetor connection boots for cracks and leaks

Check idle setting

Check bleeder hoses for damage and kink-free arrangement

Check cooling system for leaks, antifreeze protection

Check radiator fan for proper operation

Check exhaust system for leaks and suspension

Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them

Check the oil level in the master cylinder of the hydraulic clutch

Clean air filter and air filter box

Check cables for damage and kink-less arrangement

Check headlamp adjustment

Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)

Make sure all screws and nuts are tight

Check brake fluid level, lining thickness, and brake discs

Check brake lines for damage and leaks

Check/adjust smooth operation, free travel of handbrake/footbrake levers

Check screws of brake system for tight fit

Check suspension strut and fork for leaks and proper operation

Check O-ring of suspension strut for wear

Clean fork dust sleeves

Bleed fork legs

Check swinging-fork pivot

Check/adjust steering-head bearing

Lubricate reversing lever

Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, swinging-fork pivot, reversing lever, suspension strut)

Check spoke tension and rim joint

Check tire condition and inflation pressure

Check chain and chain guides for wear, force fit and tension

Check screws on pinion and chain sprocket for locking devices and a tight fit

Lubricate chain

Check wheel bearings and jerk damper for play

1. Service after

1000 km

z z z z z z z z z z z z

2. Service after / every

5000 km

z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

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

Perform complete suspension strut maintenance

Perform complete reversing lever maintenance

Clean and lubricate steering-head bearing and sealing elements

Clean and adjust the carburetor

Treat the electrical contacts and switches with contact spray

Treat battery connections with contact grease

Change the brake fluid z z z z z z z

IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

Service intervalls should never be exceed by moor than 500 km.

Maintenance work done by KTM authorised workshops is not a substitute of care and checks done by the rider!

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

Check oil level

Check brake fluid level

before each start

z z

after every cleaning

Check brake pads for wear

Check lighting system for proper operation

Check horn for proper operation

Lubricate and adjust actuating cables and nipples z z z z

Bleed fork legs in regular intervals

Remove and clean fork dust sleeves in regular intervals

Clean and lubricate chain as necessary

Check chain tension

Clean air filter and filter box (depending on the dirt accumulation)

Check tire pressure and wear

Check coolant level

Check fuel lines for leaks

Drain float chamber

Check all control elements for smooth running

Check brake performance z z z z z z z z z

Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents

Treat ignition/steering lock and light switch with contact spray

Check all screws, nuts, and hose clamps for their tight fit z z

for cross country use once a year

z z z z z z

MAINTENANCE WORK ON CHASSIS AND ENGINE

ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFES-

SIONAL. 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.

– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE

THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC.

– WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING

DEVICES. IF THE MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK

– DO NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS

AND KEEP WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS.

– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

– DISPOSE OF OIL, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS.

– UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER USED

OIL CONTAMINATES 1,000.000 LITERS WATER.

– IF YOU UNSCREWED ANY SCREWED CONNECTIONS WITH SELF-LOCKING NUTS, THEY MUST BE REPLACED WHEN MOUNTING. IF NO SELF-

LOCKING NUTS ARE AVAILABLE, APPLY LOCTITE 243 TO THE THREAD. THE SCREWS AND NUTS MUST BE REPLACED IF THE THREAD IS

DAMAGED.

– ALL SCREWS AND NUTS MUST BE TIGHTENED TO THE SPECIFIED TORQUE FIGURES USING A TORQUE WRENCH. IF SCREWS OR NUTS

ARE NOT ADEQUATELY TIGHTENED, THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO GO OUT OF CONTROL WHILE YOU DRIVE.

TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS.

Tool set (LC4 Enduro)

The tool set [1] is located in the tool box under the right side cover.

Removing the seat (LC4 Enduro)

Remove the collar screws

[2] from the underside of the fender. Lift the rear of the seat, pull backwards, and unhook it from the oval-head screw

[3].

To mount the seat hook it into the oval head screw, lower the rear part of the seat and push the whole seat forwards. If necessary push the middle of the seat slightly down to let the retaining bracket [4] engage with the seat. Finally fasten the seat with the corresponding screw.

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 *

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

[4] of the top triple clamp and turn steering stem bolt clockwise

[5] until there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly rap on the triple clamp to avoid tension. Re-tighten the five clamp screws with 20 Nm.

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE

MOTOR-CYCLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET

OUT OF CONTROL.

IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI-

ODS, FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL

BE DESTROYED.

At least once a year, the steering head bearings should be greased.

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. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical maintenance service.

EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE

FORK. IF YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER

PLUGS BEFORE HAVING THE SEALS REPLACED.

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows [2] are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak.

Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward.

Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine oil. Then, push the dust-protection bellows into the outer tubes by hand.

NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD

CONSIDERABLY REDUCE THE TIRE'S ROAD GRIP AND THE BRAKING EFFECT OF

THE FRONT BRAKE.

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]. 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.

– One rotation of the adjusting ring [2] changes the spring preload by approximately 1.75 mm (0.07 in).

A

Loosen the locking ring

[1] with the hook wrench from the tool set. Change the spring preload with the adjusting ring

[2] and retighten the locking ring.

BASIC SETTING – SPRING PRELOAD:

WP 01187B03 ........................A = 23,5 mm

WP 01187B02 ........................A = 20 mm

(640 LC4 Enduro)

(640 LC4 Supermoto)

Lubricating the shock absorber linkage

The bearings in the rocker arm must be greased (Motorex Long Term 2000) in regular intervals. For this purpose, a grease nipple [3] is mounted on the rocker arm.

AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALLY IMPORTANT

TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.

min. 2,5 mm

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 (0.1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit.

NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE

REAR SHOCK ABSORBER.

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COM-

PRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO

DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE

RESULT.

MAINTENANCE WORK ON CHASSIS AND ENGINE

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.

– IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER

TRANSMISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL

BEARINGS) WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN

PREMATURE WEAR AND EVEN CHAIN BREAKAGE.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE

CHAIN JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD

ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTOR-

CYCLE.

Correct chain tension

Loosen collar nut [1], loosen counter nuts [2], and turn right and left adjusting screws [3] equally far. Tighten counter nuts [2].

Before tightening the wheel spindle, verify that the chain adjusters [4] are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel.

Tighten collar nut [1] with 80 Nm.

IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POS-

SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE.

NOTE: The large adjusting range of the chain adjusters 32mm (1.28 in) allows you to use different secondary ratios in combination with the same chain length.

The chain adjusters

[4] can be rotated by 180°.

ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

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 LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK,

EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS

WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT

OF CONTROL.

– THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS

HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE

SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL.

– NEVER MOUNT A NORMAL CHAIN JOINT.

Also check sprockets and chain guides for wear, and replace if necessary.

15 KG

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 (10.88 in) is measured. Chains do not always wear off evenly, therefore repeat the measurement at different places on the chain.

NOTE: If you mount a new chain, the sprockets should also be replaced. New chains wear faster if used on old used sprockets.

1 2 3

max. 272 mm

16 17 18

MAINTENANCE WORK ON CHASSIS AND ENGINE

LC4 Enduro

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 the caliper support with Loctite 243 and tighten to 25 Nm.

LC4 Supermoto

BRAKE CALIPERS (LC4 Supermoto):

The front brake caliper [1] has 4 brake pistons and is rigidly connected to the fork leg. The rear brake caliper has one brake piston and "floats", which means that it is not rigidly connected to the brake caliper support. The resulting lateral adjustment ensures that the brake pads [2] optimally rest against the brake disk at any time. Secure the screws [3] of the caliper support with Loctite

243 and tighten to 40 Nm.

BRAKE PADS (LC4 Enduro):

The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front and ID450 organic lining at the back.

BRAKE PADS (LC4 Supermoto):

The brake pads are fitted with ID450 organic lining

These linings provide an optimal combination of dosing, brake performance and life cycle. The lining type is stated on the back of the brake pad and also recorded in the homologation papers.

Other brake pads are available for competition sports.

BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR-

IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE

PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN

DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER-

ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT

CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF-

FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS

AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY

WILL BE VOID.

BRAKE FLUID:

KTM fills the brake systems with „Motorex Brake Fluid DOT 5.1“ brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. If you do not have any DOT 5.1 for refilling, you may use DOT

4 brake fluid. However, you should replace it as soon as possible by DOT 5.1.

Never use DOT 5 braking fluid. It is based on silicone oil and has a purple color. Gaskets and brake hoses are not compatible with it.

HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR

MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE-

QUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCK-

ETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING

THE BRAKE SYSTEM TO FAIL.

BRAKE FLUID RESERVOIRS:

The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down. In this case, consult an authorized KTM dealer immediately.

BRAKE DISCS:

Wear reduces the thickness of the brake disc in the area of contact [4] with the brake pads. At its thinnest spot [A], the brake disc must not be more than

0.4mm thinner than its nominal dimension [B]. The nominal dimension can be gaged in a location beyond the area of contact with the brake pads. Check wear in several spots.

– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM CONSTITUTE

A SAFETY HAZARD. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON

AS IT REACHES ITS WEAR LIMIT.

– AS A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CAR-

RIED OUT BY A LICENSED KTM MECHANIC.

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 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 you press the hand brake lever forwards, you should have at least 3 mm (0.12 in) free travel. Turn the adjusting screw [1] if necessary.

min. 3 mm

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 IN).

ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE

RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF

THIS FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAK-

ING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.

Changing the basic position of the handbrake lever (LC4 Supermoto)

The adjusting screw [2] allows you to change the basic position of the handbrake lever [3].

Press the handbrake lever's outer end forward, and, at the same time, turn the adjusting screw.

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.

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN

THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

5 mm

Refilling the front brake fluid reservoir *

Loosen screws

[4] and remove lid [5] and membrane [6].

If necessary, dismount the mirror and loosen the throttle grip.

Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0.2 in) below the rim with brake fluid DOT 5.1 (Motorex Brake

Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off spilled or overflowing brake fluid with water.

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR-

PLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO

IT.

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND

EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER

AND CONSULT A DOCTOR.

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

MAINTENANCE WORK ON CHASSIS AND ENGINE

min.

1 mm

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.

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER

THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN

SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

min.

1 mm

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY

OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL

RUB AGAINST THE BRAKE DISC, IMPAIRING THE BRAKING EFFECT AND DESTROY-

ING THE BRAKE DISC.

Checking the front brake pads (LC4 Supermoto)

The brake pads can be inspected from behind. Always inspect the brake pad linings before taking off on your motorcycle. They should not be thinner than

1 mm (0.04 in) which is the case when the notch [A] is no longer discernable.

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER

THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN

SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

3-5mm

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY

OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL

RUB AGAINST THE BRAKE DISC, SIGNIFICANTLY IMPARING THE BRAKING EFFECT

AND DESTROYING THE BRAKE DISC.

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop roller [1]. The free play at the foot brake pedal must then be adjusted by means of the piston rod [2].

Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20

in) of free play, before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).

NOTE: To prevent the stop roller from turning when tightening, counteract by inserting a hexagon socket wrench in hole [B] provided for this purpose.

IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE

BRAKE SYSTEM WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE

PADS.THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME

CASES.

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 LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN

THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir.

For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw [1]. Then move the container outwards as indicated in the illustration. Remove plug [2] with rubber boot [3] and add brake fluid DOT 5.1

(Motorex Brake Fluid DOT 5.1) up to the „MAX“ mark. Replace rubber boot and plug. Overflown or spilled brake liquid must be rinsed off with water. Mount the screw and fix the brake fluid reservoir to the frame, always making sure to prevent kinks in the connecting hose.

– NEVER USE DOT 5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A

PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED

TO IT.

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND

EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER

AND CONSULT A DOCTOR

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

min.

1 mm

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in).

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER

THAN 1 MM (0.04 IN), OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR

YOUR OWN SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY

OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL

RUB AGAINST THE BRAKE DISC, IMPARING THE BRAKING EFFECT AND DESTROY-

ING THE BRAKE DISC.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Dismounting and mounting the front wheel (LC4 Enduro)

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 wheel spindle [3].

Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm (0.24 in) ALLAN/IMBUS key while pulling.

Carefully remove the front wheel from the fork.

– DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN

DISMOUNTED.

– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINT-

ING UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

To install the front wheel, lift it into the fork, position and mount the axle shaft. Mount the collar nut [1], tighten the clamping screws [2] on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm.

Loosen the clamp screws on the right fork leg. Take the motorcycle down from its stand. Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment.

Only after this has been accomplished, tighten the clamp screws on both fork legs with 15 Nm.

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE

YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON

AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV-

IOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE

UNTIL THE PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY

MATTERS, EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

Dismounting and mounting the front wheel (LC4 Supermoto)

The front wheel of the Supermoto is essentially removed in the same manner as the front wheel of the LC4. However, the brake caliper has first to be removed. To remove the front brake caliper, remove both screws

[4] and pull the caliper backwards from the brake disc.

After mounting the front wheel, slide the brake caliper to the brake disc. Remove the grease from the threads of both screws [4] and apply Loctite 243. Tighten the screws with 40 Nm.

THE SCREWS [4] MUST BE SECURED WITH LOCTITE 243.

MAINTENANCE WORK ON CHASSIS AND ENGINE

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 the rear wheel as far forward as possible, take the chain from the rear sprocket and carefully take the rear wheel out of the swingarm.

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DIS-

MOUNTED.

– ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINT-

ING UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED.

– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE

AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE (MOTOREX

LONG TERM 2000) TO PREVENT THE THREAD FROM JAMMING.

NOTE: If the rear wheel has been dismounted, you should also check the shock absorption rubber.

The rear wheel is remounted in reverse order. Before tightening the collar nut to 80 Nm, push the rear wheel forwards so that the chain tensioners lie on the tension screws.

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE

YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON

AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIV-

ING BEHAVIOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE

UNTIL THE PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND

GREASE, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

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

[4] 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.

max. 5 mm

For this purpose, lie the rear wheel on a work bench with the rear sprocket upwards, and put the wheel spindle in the hub. Now hold the rear wheel firmly and try to turn the rear sprocket. The rear sprocket may not turn more than maximum 5 mm (0,2 in) measured on the outside. If the play in the chain wheel is larger, all 6 shock absorption rubbers are to be replaced.

Check the shock absorption rubbers for signs of damage and dirt.

IF THE SHOCK ABSORPTION RUBBERS ARE NOT REPLACED IN GOOD TIME, THE

REAR SPROCKET CARRIER AND THE REAR HUB WILL BE DAMAGED. ALLWAYS

REPLACE ALL 6 ABSORPTION RUBBERS, NEVER SINGLE RUBBERS.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Tires, air pressure

Tire 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 whenever you’re getting ready to go anywhere on your motorcycle.

TIRES - AIR PRESSURE 640 LC4 ENDURO

front rear

Road, Driver only 1.8 bar

Road, with passenger 2.0 bar

2.0 bar

2.2 bar

TIRES - AIR PRESSURE 640 LC4 SUPERMOTO

Road, Driver only front

2.0 bar

Road, with passenger 2.2 bar rear

2.2 bar

2.4 bar

10 sec

IN ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE, ONLY

KTM-APPROVED TIRES MAY BE USED. OTHER TIRES CAN HAVE A NEGATIVE EFFECT

ON RIDING PERFORMANCE (E.G. VIBRATION AT HIGHER SPEEDS).

Approved tires for 640 LC4

BRIDGESTONE . . . . . . . . . . . .TW 301/302

METZELER . . . . . . . . . . . . . . .Enduro 3, Enduro 4, Karoo

MICHELIN . . . . . . . . . . . . . . .Sirac, T63

PIRELLI . . . . . . . . . . . . . . . . .MT21, MT60, MT70, MT90, Scorpion Sync

– Tire type and size can be found in the technical specifications and in the homologation certificate

– Tire condition has to be checked every time you want to ride your motorcycle. Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire.

– Refer to the specific regulations in your country for minimum tire tread requirements. We recommend replacing tires at the latest when the tread is down to 2 mm (0.08 in).

– Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires.

– Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle rides.

– Use tires of the same brand and type for the front and rear wheels.

– For your own safety replace damaged tires immediately.

– Worn tires can have a negative effect on how your motorcycle performs, especially on wet surfaces.

– If air pressure is too low, abnormal wear and overheating of the tire can result.

– New wheels have a smooth surface, which means that they must be run in to achieve full grip. For this purpose, ride the motorcycle carefully at moderate speed during the first 200 kilometers with new tires, tilting the vehicle at different angles so that all sections are properly roughened. Tires will not display their full grip characteristics until they are properly run in.

– For reasons of safety, it is recommended to exchange the valve insert whenever a new tire is mounted.

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. If necessary, have the spokes retightened and the wheel centered by a KTM dealer.

– SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY

LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE.

– EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOAD-

ING.THE SPOKES MUST BE TENSIONED TO 4 NM.

Changing the wheel size

The preset wheel diameter (21, 19 or 17“) and the respective wheel circumference (2205, 2040 or 1882 mm) are displayed briefly when the ignition is switched on.

To change the wheel diameter, switch on the ignition, change to the ODO mode and press the MODE and SET buttons simultaneously for approx. 10 seconds.

The display will start to blink. Select the wheel diameter using the MODE button, press the SET button to confirm and save the setting.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Enduro

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 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.

Supermoto

– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH

GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.

– IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER.

– IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH

WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR.

– THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLO-

SIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY.

– DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN.

ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES.

– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR [2] !

– NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS

WILL DESTROY THE RECTIFIER-REGULATOR.

– THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT

(AS SHOWN IN THE ILLUSTRATION), OTHERWISE ELECTROLYTE CAN ESCAPE.

BATTERY STORAGE:

When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sunlight.

VOLT

Charging the battery

NOTE: A battery charger, item no. 58429074000 is available from your KTM dealer.

You can also use the battery charger to test the battery's off load voltage, startability and the generator capacity.

Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage).

Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring.

Recharging is not required if the voltage exceeds 12.4 V.

Recharge if the voltage is below 12.4 V.

CHARGING:

Charge the battery for 5 to a max. of 10 hours with 0.9 amperes and a max.

of 14.4 volts.

For a quick charge, do not charge the battery longer than 1 hour with 4.5

amperes and a max. of 14.4 volts.

– IF THE CHARGE CONDITION CANNOT BE ESTABLISHED, THE BATTERY MAY ONLY

BE CHARGED 5 TO A MAX. OF 10 HOURS WITH 0.9 AMPERES AND A MAX. OF

14.4 VOLTS.

– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING

THE CHARGING UNIT ON.

– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT

VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY

CHARGING PROCESS.

– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED

VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY

VALVES.

– AVOID QUICK CHARGING IF POSSIBLE.

– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.

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.

Enduro

FUSE

LC4 SUPERMOTO

10 Ampere

– electronic speedometer

– capacitor

10 Ampere

– ignition

– starter system

10 Ampere

– flasher lights

– brake light

– horn

10 Ampere

– headlight

– parking light

–

LC4 ENDURO

20 Ampere protects all power consumers against short circuits.

10 Ampere

– electronic speedometer

– capacitor

10 Ampere

– ignition

– starter system

10 Ampere

– flasher lights

– brake light

– horn

10 Ampere

– headlight

– parking light

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.

Supermoto

UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR

A FUSE ALLOWED TO BE “REPAIRED”. AN INEXPERT TREATMENT COULD DAM-

AGE THE WHOLE ELECTRICAL INSTALLATION!

Exchanging the brake light and tail light bulb (LC4 Enduro)

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 worksteps indicated above.

NOTE: Since the bulb on the tail end is subjected to higher vibrations, heavyduty bulbs are available from your KTM dealer.

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 socket.

To mount the lamp reverse the worksteps indicated above.

When changing the tail-light lamp [2], simply pull it out of the holder.

Exchanging the headlight lamp (LC4 Enduro)

Replacing the headlight bulb

Remove the headlight mask:

Remove screw [3] on the left and right.

Tilt the headlight mask to the front and detach from the lower fender.

Exchanging the headlight lamp:

Disconnect plug [4] from the bulb.

Remove the rubber cap

[5]

Unhook the retaining bracket, then remove the bulb.

When inserting the new bulb make sure that the wider of the 3 tongues

[6]

is located in the corresponding groove in the socket.

NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF

THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHER-

WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE

REFLECTOR.

Hook in the retaining bracket, mount the rubber cap and connect the plug to the bulb.

Mount the headlight mask:

Position the headlight mask such that the headlight is located under the cockpit.

Fit the headlight mask into the fender and mount screws [3].

Replacing the parking-light bulb (LC4 Enduro)

Disassemble the headlight as described above and simply pull the bulb socket

[7] out of the reflector.

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.

1 1

Replacing the headlight lamp:

Pull the plug [2] off the bulb

Remove the rubber cap

[3]

Turn the lamp base [4] approx. 30° in a counterclockwise direction and pull out of the socket.

When inserting the new bulb [5] make sure that it fits correctly in the socket.

NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF

THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHER-

WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE

REFLECTOR.

To mount, proceed in the reverse order.

Mounting the headlight mask:

Fit the headlight mask in the respective brackets.

Mount the speedometer cover and screws [1].

Replacing the parking-light bulb (LC4 Supermoto)

Disassemble the headlight as described above and simply pull the bulb socket

[6] out of the reflector.

Adjusting the headlight range (LC4 Supermoto)

The payload can make it necessary to correct the headlight range.

The headlight range can be adjusted with the adjusting screw

[7]. Turning in a clockwise direction will reduce the headlight range, turning in a counterclockwise direction will increase the headlight range.

5 m

5 cm

TO CHECK:

Determine the distance from the ground to the center of the headlight when your motorcycle is loaded and ready for the trip (baggage, driver, passenger).

Make a mark on a light wall behind a level surface at a height corresponding to the center of the headlight. Position your motorcycle loaded ready for the trip 5 meters (16,4 ft) away from the wall and switch on the low beam. The light/dark cut-off line should be 5 cm (2 in) under the mark (see drawing).

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 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. Dirty radiator fins also reduce the cooling efficiency.

If little or no air blows through the radiators, for example when riding through slow traffic or waiting at traffic lights, the coolant temperature will rise. If the coolant temperature rises to 98°C , the fan [1] on the left radiator will switch on. This fan will provide additional air circulation through the radiator thereby preventing the cooling system from overheating.

10 mm when engine is cold

THE RED TEMPERATURE WARNING LAMP FOR THE COOLING LIQUID [2] WILL BEGIN

TO BLINK WHEN THE COOLING LIQUID HAS REACHED APPROX. 120°C (246°F),

EXCEEDING THE NORMAL OPERATING TEMPERATURE.

POSSIBLE CAUSES:

– SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE:

IF POSSIBLE INCREASE YOUR RUNNING SPEED, SO THAT MORE AIR CAN BLOW

THROUGH THE RADIATORS. SHOULD THE WARNING LIGHT STILL BE ON OFF

AFTER 300 METERS, STOP IMMEDIATELY, SWITCH OFF THE ENGINE AND LOOK

FOR OTHER POSSIBLE CAUSES.

– TOO LITTLE COOLING LIQUID IN THE SYSTEM:

LET THE ENGINE COOL DOWN, AND CHECK THE SYSTEM FOR LEAKAGE’S. ALSO

EXAMINE THE COOLING LIQUID LEVEL CAUTION SCALDING HAZARD! DO NOT

DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM.

GO TO YOUR NEAREST KTM GARAGE AND GET IT SEEN TO. IF YOU DRIVE WITH

THE COOLING LIQUID TEMPERATURE WARNING LIGHT ON, YOU WILL CAUSE

EVEN MORE DAMAGES TO THE ENGINE.

– THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING:

THE COOLING FAN MUST BE RUNNING, WHEN THE COOLING LIQUID TEMPER-

ATURE IS 98°C AND THE IGNITION IS ON. IF THE FAN IS NOT WORKING, AND

THERE APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY THING YOU

CAN DO IS TO DRIVE ON TO YOUR NEAREST KTM GARAGE AT THE LEAST POS-

SIBLE ENGINE LOAD.

– CONTINUOUS USE OF THE CLUTCH (RIDING THE CLUTCH) AT LOWER SPEEDS.

A mixture of 50% antifreezer and 50% distilled water is used as cooling liquid. How-ever, the anti-freeze protection must be at least -25°C (-13°F).

Aside from antifreezing protection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water.

FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTI-

FREEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION

AND COOLANT FOAMING.

Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap [3]; a water temperature rising up to

125°C (255°F) is admissible, without fear of problems.

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.

– IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS

COLD. IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT,

USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

CAUTION - SCALDING HAZARD !

– DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE

ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS.

– IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER

RUNNING COLD WATER RIGHT AWAY!

– COOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN!

– IN CASE COOLANT IS INGESTED, GO SEE A DOCTOR IMMEDIATELY!

– IF COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDI-

ATELY AND GO SEE A DOCTOR!

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.

To clean the air filter, remove screws [1] and the filter box cover. Detach retaining clip [2] and remove the air filter [3] including the filter holder [4] from the filter box.

Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid. Motorex offers environmentally-friendly products for professional oil filter maintenance (Motorex Bio Dirt Remover + Motorex Liquid Bio Power).

Press out the water from the air filter but do not wring and allow the filter to dry. Lubricate the dry air filter thoroughly with highgrade filter oil, rubbing to coat the entire filter surface.

Clean the filter box and cover and check the carburetor connection boot for damage.

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.

– 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. FOR CLEANING PURPOSES AND TO OIL THE

AIR FILTER.

– NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE,

DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR.

– DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL-

TER IS NOT MOUNTED CORRECTLY.

Cleaning of air filter (LC4 Supermoto) *

To do this, remove the seat and the air filter cover from the air filter box. Unclap the filter holder

[5], swing back and remove air filter plus filter carrier from the filter box.

Press out the water from the air filter but do not wring and allow the filter to dry. Lubricate the dry air filter thoroughly with highgrade filter oil, rubbing to coat the entire filter surface.

Clean the filter box and cover and check the carburetor connection boot for damage.

Mount the air filter on the filter support

[6]. Grease the front side [A] of the filter, to improve the seal. Mount the air filter and the filter support in the filter box. Make sure they are centered

[B], and lock into place with the filter holder

[5].

– DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM-

AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY

„MOTOREX“ FOR AIR FILTER MAINTENANCE.

– NEVER OPERATE YOUR MOTORCYCLE WITHOUT AIR FILTER. OTHERWISE,

DUST AND DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR.

– HAVING MOUNTED THE AIR FILTER, CHECK IT FOR CORRECT FIT. THE FRONT

END A MUST ABOUT THE AIR FILTER BOX. OTHERWISE, DUST AND DIRT MAY

GET INTO THE ENGINE AND LEAD TO INCREASED WEAR.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Exhaust system (LC4 Supermoto) *

640 Supermoto silencers are filled with glass-fiber yarn in the front and insulation 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 effect, therefore only the front glass-fiber yarn set

[1] must be replaced.

To replace, detach the silencer from the motorcycle and remove the front cap

[2]. Pull the front glass-fiber yarn set including the inner exhaust pipe [3] out of the silencer. Clean the front inner exhaust pipe.

Slide a new set into the silencer.Replace O-Ring [4]. Then push the inner exhaust pipe into the silencer and mount the cap.

THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN-

NING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL

IT HAS PROPERLY COOLED DOWN.

Changing the original position of the clutch lever

The adjusting screw

[5] 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 counterclockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw clockwise increases the distance between the clutch lever and the handlebar.

ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER-

TAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY

EXCESSIVE FORCE.

Checking the oil level of the hydraulic clutch *

To check the oil level in the master cylinder of the clutch remove the cover.

For this purpose, remove screws [6] and cover [7] together with the rubber boot [8]. The oil level in the horizontal-standing master cylinder should be 4 mm (0.16 in) below the upper edge.

If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungsfluid

75), available from your authorized KTM workshop.

KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC

CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE

ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK-

SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY. NEVER REFILL WITH

BRAKE FLUID.

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).

4 mm

IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER

SYSTEM CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CON-

SUMPTION, AN UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON

AND CYLINDER.

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 lock nut and slide protecting cap back on.

Mount the tank and seat.

3-5 mm

25 mm

Checking the adjustment of the hand decompression cable *

To check, set piston at compression, so that the valves are closed. While doing this, slowly operate the kickstarter through its stroke until the clicking sound

(disengaging) of the automatic decompression can be heard. Now the decompression lever must be operated 25 mm (1 in) until resistance is felt (the exhaust valves begin to open). To adjust move back the protective cover [4], loosen the counter nut and correct the adjusting screw [5] accordingly. Tighten counter nut and push back protective cover.

IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER, THIS CAN RESULT IN ENGINE

DAMAGE.

note: No adjustment need be made to the automatic decompressor.

Adjust the throttle cable *

When starting to turn the throttle grip, you should feel an initial backlash of

3-5 mm (0.12-0.2 in).

If a correction is necessary, start by removing the tank. Slide back the protection cover [6]. To set the backlash, loosen the counter nut [7] and turn the adjusting screw [8] 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.

To check the correctness of this setting, start the engine, turn the handlebar left and right, in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise, you have to increase the backlash of the throttle cable.

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 connectors are connected to each other, the ignition curve for fuel having at least 95 octane (ROZ) is activated.

If you disconnect the plug and socket connection, the ignition curve for fuel having 80 - 94 octane (ROZ) is activated. Although this causes the engine to lose some of its power output, it prevents poor glow ignitions and engine damage.

IF FUEL HAVING AT LEAST 95 OCTANE (ROZ) IS NOT AVAILABLE, THE IGNITION

CURVE FOR 80 - 94 OCTANE (ROZ) MUST BE ACTIVATED TO PREVENT ENGINE

DAMAGE.

Adjust idling speed *

Use the adjusting screw [2] to adjust the basic position of the throttle valve and, thus, the idle speed.Turning in clockwise direction will increase the idling speed, turning in counterclockwise direction will reduce the idling speed. Normal idling speed 1400 - 1500 rpm.

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 hose

[3] that leads downward behind the engine into a collecting vessel.

Open the drain plug [4] (turning it counterclockwise) by several turns, and drain the fuel from the float chamber.

Then, retighten the drain plug and open the fuel tap.

FUEL IS HIGHLY FLAMMABLE AND TOXIC. BE EXTREMELY CAUTIOUS WHEN HAN-

DLING FUEL. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN

FIRE OR BURNING CIGARETTES. ALWAYS ALLOW THE ENGINE TO COOL DOWN FIRST.

WIPE UP ANY SPILT FUEL IMMEDIATELY. MATERIALS SATURATED WITH FUEL ARE

HIGHLY FLAMMABLE, AS WELL. IF YOU HAVE ACCIDENTALLY SWALLOWED FUEL

OR IF IT HAS GOTTEN INTO YOUR EYES, GO SEE A PHYSICIAN IMMEDIATELY.

MAINTENANCE WORK ON CHASSIS AND ENGINE

5W/40

JASO T903 MA

TEMPERATUR

0°C

32°F

10W/50

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 require long changing intervals, motorcycle engines require a higher power output at higher speeds. Most motorcycle engines also use the same oil to lubricate the transmission and the clutch. The JASO MA standard responds to these special requirements.

Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can).

KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F)

5

10

7

11

12

4

Checking the engine oil level

The engine oil level can be checked when the engine is cold or warm.

To check, place the motorcycle in an upright position on a level surface (center stand).

If the engine is cold, the oil level should be visible at the lower edge [A] of the inspection glass.

If the engine is warm, the oil level should be visible at the upper edge [B] of the inspection glass.

Add engine oil if necessary.

– INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMA-

TURE WEAR IN THE ENGINE.

– DO NOT OVERFILL THE ENGINE CASE.

– DO NOT UNDERFILL THE ENGINE CASE.

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 off. Then the motor oil flows through the fine screen filter

[6] that removes even the finest of contaminants from the motor oil. The cleansed motor oil is pumped via an oil line and the clutch cover into the crankshaft to the conrod bearing [7] and drains from there into the crank case. A additional oil pump [8] suctions the motor oil out of the crank case and pumps it through the oil canal [9] to the gear wheels of the 4th and 5th gears. The motor oil reaches the oil sump via the gear wheels. The timing chain [10] also dips into the oil sump and propels motor oil upwards to the cylinder head.

The motor oil reaches the carnshaft [11] and the valves through the bore [12].

6

8

1

2

9

3

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 breast pipe and to de-aerate the oil system.

If the oil system is not bled at all or bled insufficiently, the bearings of the engine will not get enough lubrication, which in turn may result in engine failure.

Therefore, we recommend that you have the engine oil changed by your authorized KTM mechanic. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void.

The engine oil change is to be carried out when the engine is still warm.

AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT IS VERY HOT

- DO NOT BURN YOURSELF.

Place the motorcycle on a horizontal surface. Remove the two plugs [13] and

[14], and drain oil into a container.

PLUG [A] MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.

Remove the screws and the cover [15]. Loosen the fine screen filter [6] with an oil filter wrench and then screw it off by hand.

The screw [16] must be removed to allow the motor oil to flow out of the frame breast pipe.

Clean the plugs thoroughly with petroleum and compressed air in order to remove any metal filings. After the oil has drained completely, clean the sealing areas and remount the plugs together with their gaskets. Tighten plug

[13]

with 30 Nm and plug [14] with 20 Nm. Tighten the screw [16] with

10 Nm. Clean sealing surfaces on the frame breast pipe [17], fill new fine screen filter with engine oil, and oil rubber gasket [18]. Replace fine screen filter and screw it back in place, your bare hand will do.

Remove oil dipstick on the clutch cover, fill with 1.3 litre (0.34 US gallons) engine oil and attach plug again.

– USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. USING ANOTHER FILTER

BRAND CAN RESULT IN DAMAGE TO THE ENGINE.

– IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE

FRAME, YOU MUST BLEED THE OIL SYSTEM!

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 plastic hose onto the hose connection piece, and you will have your filling tool.

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, and let it idle

(approx. 20 seconds) until oil escapes at the hole

[A]. As soon as oil begins to leak out, switch off the engine, mount the plug and gasket and tighten to

25 Nm.

Let the motor run until it warms. Check the oil drain plugs and the fine screen filter to make sure they are properly sealed. Check the level of the motor oil.

Place the motorcycle on a horizontal surface (main stand) and wait for 5 minutes.Checking the oil level, he should be between the two marks on the inspection glass, however, it must never rise above the MAX mark. Otherwise, engine oil would get into the air filter box by way of the engine venting system. Add engine oil, if necessary.

– INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF

THE ENGINE.

– CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN

A FALSE READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL

LEVEL.

– DO NOT OVERFILL THE ENGINE CASE.

– DO NOT UNDERFILL THE ENGINE CASE.

Afterwards check the entire oil system and motor to make sure they are properly sealed. Attach the covering of the fine screen filter to the frame breast pipe.

Note: Dispose of used oil properly! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter (0.264

US gallons) oil contaminates 1.000.000 liter (264.000 US gallons) water.

Changing oil filter *

Replace the oil filter when changing the engine oil. Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. Remove banjo bolt

[2] and the three screws. Remove oil filter cover [3] and oil filter. Clean the filter case, oil filter cover and sealing areas. Make sure the oil duct in the oil filter cover is not clogged.

Place the new oil filter [4] on the connection in the oil filter cover and mount together with a new seal [5]. Tighten the 3 screws in the filter cover to 5 Nm.

Tighten the hollow screw with seals and tighten to 15 Nm.

Finally, start the engine and check the oil system for leakage.

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 of uncertainty, please contact a KTM-dealer.

TROUBLE

Engine doesn’t crank.

CAUSE

Operating errror

Discharged battery.

REMEDY

Turn on the ignition, switch the gear to neutral and switch the emergency OFF switch on.

Recharge the battery and investigate the causes for discharging; contact a KTM dealer.

The engine doesn't crank. The neutral indicator lamp doesn't light up.

Defect ignition lock or emergency

OFF switch

Blown fuse safe-starting system.

Check ignition lock and emergency OFF switch, contact a

KTM dealer.

Enduro: Replace fuse (3).

Supermoto: Replace fuse (2).

Blown main fuse.

Remove seat and replace the main fuse. If fuse blows again contact a KTM dealer.

Contact a KTM dealer.

The engine cranks only with pulled clutch lever

Defect safe-starting system.

Engine cranks with gear engaged. Defect safe-starting system.

Contact a KTM dealer.

Engine cranks but doesn’t start.

Operating error

The motorcycle has been out of operation for a longer period of time.

Therefore old fuel has accumulated in the float chamber

The easily inflammable components of the new fuels evaporate during longer periods of standstill.

When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel.

Fuel supply interrupted

Open fuel tap, tank fuel, you did not use choke. Pay attention to starting off information (see driving instructions).

Flooded engine

Place a vessel underneath, remove the drain plug from the carburetor and open the fuel cock,

– if fuel leaks out, the carburetor might need cleaning

– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

Fully open the throttle when starting or exchange the spark plug, respectively

Sooty or wet spark plug

Electrode gap too large

Clean and dry the spark plug or exchange it, respectively

Adjust spark plug elektrode gap to 0,9 mm (0.036 in)

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.

– If a spark now occurs, replace spark plug cap

– If no spark is produced, control ignition system

The plug connection of the CDIunit, the pulse generator or the ignition coil has oxydized

Remove the seat, the right side cover and the fuel tank. Clean the plug connection and treat it with contact spray

Water in carburetor or jets blocked Dismount and clean carburetor

Claped out side stand

Faulty side stand switch

Clap up side stand

Renew side stand switch

TROUBLE SHOOTING

TROUBLE

Engine fails to idle

CAUSE

Glogged idling jet

REMEDY

Disassemble carburetor and clean jets

Oncorrect adjustment of adjusting screws on carburetor

Have carburetor adjusted

Defective spark plug Replace spark plug

Engine does not rev high

Engine will not reach full power

Engine overheats

Defective ignition system Have ignition system checked

Carburetor fuel level too high because

Dismount carburetor and check if worn out

Float needle is dirty or worn out

Float leaks

Replace float needle

Replace float

The cold starting system is permanently activated due to a lack of play in the choke cable.

Adjust choke cable.

Defective membrane of slide

Carburetor leaking

Replace membrane

Check vacuum hose and venting hose of carburetor for correct position (no kinks)

Tighten jets Loose carburettor jets

Electronic ignition timing faulty Have ignition system checked

Fuel supply partically interrupted or carburetor dirty

Clean and check fuel system as well as carburetor

Float leaks

Defective membrane of slide

Carburetor leaking

Radiator fins are extremely dirty

Foam forms in cooling system

Bent radiator hose

Thermostat defective

Blown fan fuse

Defect thermoswitch

Fan defective

Replace the float

Replace membrane

Check vacuum hose and venting hose of carburetor for correct position (no kinks)

Air filter very dirty

Valve clearance to small

Clean or replace air filter, contact a KTM dealer

Have valve clearance adjusted

Loss of compression because hand decompressor has no play

Check setting of the hand decompression cable

Electronic ignition timing faulty

Insufficient cooling liquid

Have ignition system checked

Refill cooling liquid (see maintenace work), check cooling system for leaks

Clean radiator with water jet

Replace cooling liquid, use antifreezer with brand name

Shorten or replace cooling hose

Remove and check thermostat (opening temperature 70°C

(157°F) or replace it, contact a KTM dealer

Replace fuse and check if fan operates properly (see below)

Contact a KTM dealer

Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermoswitch (bottom right radiator), contact a KTM dealer

TROUBLE SHOOTING

TROUBLE

High oil consumption

CAUSE

Buckling gear ventilation hose

Engine oil level too high

Engine oil too thin (viscosity)

REMEDY

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 fail Blown fuse

Flasher lights, brake light, fan and horn fail

Blown fuse

The NEUTRAL lamp is not on even though the gear is in NEUTRAL

Defect neutral switch.

Loose connections, defect cable.

Enduro: Replace fuse (5).

Supermoto: Replace fuse (4).

Enduro: Replace fuse (4).

Supermoto: Replace fuse (3).

Connect cable to ground; neutral switch must be replaced if indicator lamp lights up.

Check connections and cables.

The battery is discharged The ignition (power consumer) hasn’t been switched off echarge the battery according to the relevant instructions.

The battery isn’t charged by the generator because

Remove seat and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer.

No values are visible in the

Tripmaster display

Main fuse melted through Replace the main fuse under the seat

No speed display.

Defective sensor cable or oxidized socket connector.

Check the sensor cable for damage and replace it if necessary.

Remove the headlight mask and check the socket connector.

Contact a KTM dealer.

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.

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. AND CAUSE DISTURBINGS OR

LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS.

– You should use normal trade-mark detergents to clean the engine. Strongly dirted parts should be cleaned additionally with the help of a paint brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. Due to the heat, the water also evaporates at the unapproachable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate.

– After the motorcycle has cooled down, oil and grease all sliding and pivot points. Treat the chain with a chain spray too.

– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, light switch and the socket connectors with contact spray.

CONSERVATION FOR WINTER OPERATION

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive road salt.

– Clean motorcycle thoroughly and let it dry

– Treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion agent

KEEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE

THE BRAKING POWER.

AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

STORAGE

Should you desire to make a pause over a longer space of time, please observe the following instructions:

– Clean motorcycle thoroughly (see chapter: CLEANING)

– Change engine oil, oil filter and fine screen filter (old engine oil contains aggressive contaminations).

– Check antifreezer and amount of cooling liquid.

– Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug of the float chamber to remove the remaining fuel.

– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug.

– Set piston to compression so that the valves will be closed (slowly operate the kickstarter, until you can hear the automatic decompressor click (release)

– Let fuel flow out of tank into an appropriate container.

– Correct tire pressure.

– Lubricate pivot points of the control levers, foot rests, etc. as well as the chain.

– Service the shock absorber linkage

– Disassemble and charge battery (see chapter: BATTERY).

– The storage place should be dry and not subject to excessive temperature fluctuations.

– Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion.

IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED

UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST

TO RUST.

RE-INITIATION AFTER TIME OF STORAGE

– Mount the charged battery (regard polarity) and set the clock.

– Fill up tank with fresh fuel.

– Check motorcycle as before each start (see driving instructions).

– Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics’ shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

TECHNICAL SPECIFICATIONS - CHASSIS

Frame

Fork

Wheel travel front/rear

Rear suspension

Front brake

640 LC4 ENDURO

Central chrome-moly-steel frame

640 LC4 SUPERMOTO

WP Suspension – Up Side Down 4357 MXMA WP Suspension - Up Side Down 4860 MXMA

275 / 275 mm 275 / 260 mm

Central shock absorber (WP BAVP) with PRO-LEVER linkage to rear- swing-arm with needle bearing

Disc brake with carbon-steel brake disc,

2-piston brake caliper floated

Disc brake with carbon-steel brake disc,

4-piston brake caliper

Front brake disc

Rear brake

Tyres front

Air press. road, driver only

Air press. road with passenger

Tyres rear

Air press. road, driver only

Air press. road with passenger

Fuel tank capacity

Final drive ratio

Chain

Headlight

Parking light

Instrument lights

Indicator lamps

Brake light

Rear light

Flasher light

License plate illmination

Battery

Steering angle

Wheel base

Seat high

Ground clearance

Dead weight without fuel

Ø 300 mm

16:42t

5/8 x 1/4" X-Ring

Ø 320 mm

Disc brake with carbon-steel brake disc B 220 mm (8.8 in), brake caliper floated

90/90-21

1.8 bar

2.0 bar

120/70-17

2.0 bar

2.2 bar

130/80-18

2.0 bar

2.2 bar

11.2 liter, 2.5 liter reserve

160/60-17

2.2 bar

2.4 bar

17:42t

H4 12V 60/55 W (socket P43t)

12V 5W (socket W2,1x9,5d)

LED

12V 21/5W (socket BaY15d)

12V 10W (socket Ba15s)

12V 5W (socket W2,1x9,5d) maintenance-free battery 12V 8,6 Ah

62°

1510 ± 10 mm (59.4 ± 0.4 in)

910 mm

H4 12V 60/55 W (socket P43t)

12V 5W (socket W2,1x9,5d)

LED

12V 10W (socket Ba15s)

12V 5W (socket W2,1x9,5d)

12V 10W (socket Ba15s)

12V 5W (socket W2,1x9,5d)

63°

300 mm

144 kg

Max. permissible front axle load 150 kg

Max. permissible rear axle load 200 kg

Max. permissible laden weight 350 kg

910 mm

280 mm

145 kg

STANDARD ADJUSTMENT - FORK

640 LC4

Enduro

640 LC4

Supermoto

Compression adjuster 20

Rebound adjuster 12

Spring

WP 05187B02 WP 14187B07

4.2 N/mm

4.6 N/mm

Spring preload

Air chamber length

Fork oil

5 mm

150 mm

SAE 5

28 mm

110 mm

SAE 5

STANDARD-ADJUSTMENT - SHOCK ABSORBER

640 LC4

Enduro

640 LC4

Supermoto

WP 01187B03 WP 01187B02

Compression adjuster 3

Rebound adjuster 7

Spring

Spring preload

66 / 260

23.5 mm

70 / 260

20 mm

TECHNICAL SPECIFICATIONS - CHASSIS

TIGHTENING TORQUES - CHASSIS

Collar nut front axle

Collar nut rear axle

Shock absorber top

Shock absorber bottom

Collar screws brake disk front/rear

Screw brake caliper front (Enduro)

Screw brake caliper front (Supermoto)

Bearing bolt linkage arm/frame

Collar nuts rocker arm bolts

Engine mounting screw

Ball joint for push rod

Sprocket screws on nuts

Hexagon nut swingarm bolt

Clamping screws top triple clamp

Clamping screws bottom triple clamp

Clamping screws fork stubs

Screws handlebar clamp

Allen head screw handle bar support

Bleeder screw oil reservoir frame

Spoke nipple

Other screws on chassis

Other collar nuts on chassis

M10

M14x1.5

M10

M16x1.5

WS 7

M10

M16x1.5

M20x1.5

M10

M6 (10.9)

M10

M12

M14x1.5

40 Nm

80 Nm

45 Nm

Loctite 243 + 10Nm

Loctite 243 + 25 Nm

Loctite 243 + 45 Nm

60 Nm

100 Nm

45 Nm

Loctite 243 + 25 Nm

Loctite 243 + 35 Nm

100 Nm

20 Nm

15 Nm

Loctite 243 + 20 Nm

25 Nm

4 Nm (3 - 6 Nm)

10 Nm

25 Nm

45 Nm

15 Nm

30 Nm

50 Nm

TECHNICAL DATA – ENGINE

ENGINE

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

Engine oil

Engine oil quantity

Primary ratio

Clutch

Transmission

Gear ratio

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 balancer shaft and electric starter

625 cc

101 / 78 mm

11.7 : 1 unleaded premium gasoline with at least RON 95 (USA = Premium RON 91) (RON 80-94 for other ignition curve

4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain

249/1

Intake: 36 mm Exhaust: 32 mm

Intake: 0.12 - 0.15 mm Exhaust: 0.12 - 0.15 mm

2 cylinder roller bearing needle bearing bronze bushing forged aluminium alloy

1 compression ring, 1 taper face ring, 1 oil scraper ring two Eaton-oilpumps see bellow # appr. 2.1 liters including frame straight geared spur wheels 31 : 79 teeth multi disc clutch in oil bath, hydraulically operated

5-speed claw shifted

1 st

2 nd

3 rd

4 th

5 th

14:35

15:24

18:21

20:19

22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K5

TPS

12V 200W

NGK DCPR 8 E

0.9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump

1 liter, 50% antifreeze, 50% distilled water, at least –25 ° C (–13 ° F) electric starter and kickstarter

JASO T903 MA

5W/40

TEMPERATURE

0°C

32°F

10W/50

BASIC CARBURETOR SETTING

640 LC4 Enduro

Type

Main jet

Needle jet

Idling jet

BST40-266

152,5

X-6 689

Jet needle

Needle clip pos. f. top

Mixt. adj. screw open

6G5

3rd from top

2.25

640 LC4 Supermoto

BST40-273

165

X-6 689

6G5

3rd from top

2.25

Engine oil

Only use fully synthetic engine oils that meet the JASO

MA quality requirements (see information on the can).

KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40

(for temperatures under 0°C, 32°F).

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 lever

(LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Adjusting the headlight range (LC4 Supermoto) . . . . .36

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Bleeder screws for telescopic fork . . . . . . . . . . . . . . .22

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .25

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .44

Changing the basic position of the foot brake pedal . .28

Changing the basic position of the handbrake lever

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Changing the original position of the clutch lever . . . .39

Changing the spring preload of the shock absorber . . .23

Changing the wheel size . . . . . . . . . . . . . . . . . . . . . .32

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .33

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Check the following before each start . . . . . . . . . . . .14

Checking and adjusting steering head bearing . . . . . .21

Checking and adjusting the choke cable play . . . . . . .40

Checking chain tension . . . . . . . . . . . . . . . . . . . . . .24

Checking of brake fluid level - front brake . . . . . . . . .27

Checking rubber ring on the WP rear shock absorber . .23

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .32

Checking the adjustment of the hand decompression cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Checking the cooling liquid level . . . . . . . . . . . . . . .37

Checking the engine oil level . . . . . . . . . . . . . . . . . .42

Checking the front brake pads (LC4 Enduro) . . . . . . .28

Checking the front brake pads (LC4 Supermoto) . . . . .28

Checking the oil level of the hydraulic clutch . . . . . . .39

Checking the rear brake pads . . . . . . . . . . . . . . . . . .29

Checking the shock absorption rubbers in the rear hub . .31

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Cleaning of air filter (LC4 Supermoto) . . . . . . . . . . . .38

Cleaning the air filter (LC4 Enduro) . . . . . . . . . . . . . .38

Cleaning the dust sleeves of the telescopic fork . . . . .22

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .10

Compression damping of fork . . . . . . . . . . . . . . . . .12

Compression damping of shock absorber . . . . . . . . . .12

Conservation for winter operation . . . . . . . . . . . . . . .48

Cooling liquid temperature display . . . . . . . . . . . . . . .8

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .24

Dismounting and mounting the front wheel (LC4 Enduro) . .30

Dismounting and mounting the front wheel (LC4

Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Dismounting and mounting the rear wheel . . . . . . . . .31

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Draining the carburetor float chamber . . . . . . . . . . . .41

Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . .14

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Page

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Exchanging the brake light and tail light bulb

(LC4 Enduro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Exchanging the brake light and tail light bulb

(LC4 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Exchanging the headlight lamp (LC4 Enduro) . . . . . . .35

Exchanging the headlight lamp (LC4 Supermoto) . . . .36

Exhaust system (LC4 Supermoto) . . . . . . . . . . . . . . .39

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

General informations about KTM disc brakes . . . . . . .26

General tips and warnings for starting the motorcycle . .13