KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
by KTM SPORTMOTORCYCLE AG, AUSTRIA

All rights reserved

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION
The 640 LC4 models are designed to withstand normal use on roads and easy terrain (unpaved 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.
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
Page SERIAL NUMBER LOCATIONS..5 Chassis number..5 Engine number, engine type..5 OPERATION INSTRUMENTS..5 Clutch lever...5 Hand decompression lever..5 Hand brake lever..6 Choke lever...6 Ignition lock with 3 switch positions..6 Multi-functional digital speedometer.7 Setting options in the display..8 Indicator lamps..9 Tachometer...9 Combination switch...10 Starter tip switch, emergency OFF switch, light switch10 Filler cap...10 Fuel taps...10 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 Baggage carrier...12 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE14 Instructions for initial operation..14 Running in...14 DRIVING INSTRUCTIONS...15 Check the following before each start.15 Starting when the engine is cold..16 Starting when the engine is waorm or hot..16 What to do when the engine is flooded.16 Kickstart instructions..17 Starting off...17 Shifting, Riding...17 Braking...17 Stopping and parking..18 Refueling..18 PERIODIC MAINTENANCE-SCHEDULE..20 MAINTENANCE WORK ON CHASSIS AND ENGINE.22 Tool set...22 Removing the seat...22 Checking and adjusting steering head bearing.23 Bleeder screws front fork..23 Cleaning the dust sleeves of the telescopic fork..23 Changing the spring preload of the shock absorber.24 Checking rubber ring on the WP rear shock ansorber 24 Lubricate shock absorber linkage.24 Checking chain tension...25 Correct chain tension..25 Page Chain maintenance..26 Chain wear...26 General information about KTM disc brakes..27 Adjusting of free travel at the hand brake lever..28 Checking of brake fluid level - front brake..28 Refilling the front brake fluid reservoir..28 Checking the front brake pads..28 Changing the basic position of the foot brake pedal.29 Check the rear brake fluid level..29 Refilling the rear brake fluid reservoir..29 Checking the rear brake pads..29 Dismounting and mounting the front wheel.30 Dismounting and mounting the rear wheel.30 Checking the shock absorbtion rubbers in the rear hub.31 Tires, air pressure..31 Checking spoke tension..32 Socket for electric accessories..32 Battery...33 Charging the battery..33 Fuses...34 Removing and mounting the headlight mask.34 Replacing the headlight bulb..34 Exchanging the brake light and tail light blub.35 Removing the tank..35 Cooling system...36 Checking the cooling liquid level..36 Cleaning the air filter..37 Adjusting the throttle cable..38 Checking the oil level of the hydraulic clutch.38 Changing the orginal position of the clutch lever.38 Adjusting the choke cable play..39 Checking the adjustment of the hand decompression cable.39 Adjusting idling speed..39 Draining of float chamber of the carburetor..40 Engine oil..40 Checking the engine oil level..40 Oil circuit..41 Oil and fine screen filter change, bleeding of the oil system.41 Changing oil filter...42 TROUBLE SHOOTING...43 CLEANING...46 CONSERVATION FOR WINTER OPERATION.46 STORAGE...46 Re-initation after time of storage.46 TECHNICAL SPECIFICATIONS - ENGINE.48 TECHNICAL SPECIFICATIONS - CHASSIS..50 HEAD WORD INDEX...52 WIRING DIAGRAM..APPENDIX

COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING. ALWAYS TURN ON THE LIGHT MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL. 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. THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE. OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE. ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS. DRIVE CAREFULLY ON UNKNOWN ROADS REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, YOU WILL BE PRACTICALLY BLIND. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING.

Running in

Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time. Therefore, every engine must be run in. For this reason, do not demand maximum performance from the engine for the first 100 kilometers. The vehicle must be run in at low, changing performance level for the first 1000 KM (620 miles). The maximum number of revolutions per minute must not go exceed 4800 rpm. Do not accelerate the engine up to the red mark on the tachometer (8500 r.p.m.) during a running-in period of 1000 km. Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine.

DRIVING INSTRUCTIONS

Check the following before each start
When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks. 3 CHAIN A loose chain can fall off; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear to the chain and rear sprockets. 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 reduce 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 garage, as complete failure of the braking system can be expected. Also check the state of the brake hoses and the thickness of the brake linings. Check free travel at hand brake lever and foot brake pedal. WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY (TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DONT RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. 6 CABLES Check correct setting and easy running of all control cables. 7 COOLING LIQUID Check the level of cooling liquid when the engine is cold. 8 ELECTRICAL SYSTEM Check headlight, parking light, tail light, brake light, flashers, indicator lamps and horn for faultless operation. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened.

Starting when the engine is cold
7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the choke lever 3. Operate the starter tip switch 4 without accelerating. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Swing up the centerstand 9 Switch on the light before setting off. DO WARNING
NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
CAUTION ! MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. DONT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DONT REV ENGINE WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN MIND THAT THE ENGINE SHOULD BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M. !
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: 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.
THE ELECTRIC STARTER DOESNT CRANK THE ENGINE WHEN THE STARTER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELECTRIC CURRENT IS AVAILABLE: Pull the hand decompression lever 5, start and release the lever.
Starting when the engine is warm or hot
7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the starter switch 4 without accelerating. Swing up the centerstand Switch on the light before setting off.
What to do when the engine is flooded
The throttle must be fully opened when starting. If necessary change spark plug.
Starting the engine with the kickstarter
Be sure to kick up the side or center stand before you start the engine to avoid any damage.Start as described above, then push the kickstarter hard all the way. IF WARNING
YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK THE KICKSTARTER. ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED THROTTLE GRIP INCREASE THE KICKBACK HAZARD.

NOTE REGARDING THE CENTER STAND: We advice 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 motocycle backwards at an angle as illustrated (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely.

Refueling

The LC4 engine needs premium gasoline with an octane number of 95 or higher. CAUTION ! USE UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. BE CAREFUL NOT TO LET FUEL DRIP ON THE PAINTED PARTS, WIPE UP ANY SPILLS IMMEDIATELY. THE FUEL WILL DISCOLOR THE CLEAR COAT AND MAKE IT TURN YELLOW. ! Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). WARNING 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 GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTORS ADVICE IMMEDIATELY.
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 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

YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
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 A accordingly. This is easily done. NOTE: Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring. One rotation of the adjusting ring 1 changes the spring preload by approximately 1,75 mm (0,07 in). Loosen the locking ring 2 with the hook wrench from the tool set. Change the spring preload with the adjusting ring 1 and re-tighten the locking ring.
BASIC SETTING SPRING PRELOAD WP 0118X726.. A = 27 mm (0,9 in)
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. CAUTION ! ! NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER. THE WARNING
DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

min. 2,5 mm

Lubricating the shock absorber linkage
The bearings in the rocker arm must be greased in regular intervals. For this purpose, a grease nipple 3 is mounted on the rocker arm. ! AFTER CAUTION !
EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALLY IMPORTANT TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.

Checking chain tension

Support the motorcycle on the center stand or side stand, respectively. Switch transmission to neutral. Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sliding component until the upper part of the chain is tensioned (see illustr.) Now, the distance A between chain and swingarm should be 0 mm. The upper part of the chain B must be tight (see illustr.). Correct chain tension, if necessary! IF WARNING

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 MOTORCYCLE.
15:45 16:42 A = 0 mm 17:42

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 (59 ft.lb). IF WARNING
YOU DONT 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 BEHAVIOR OF YOUR MOTORCYCLE.
NOTE: The large adjusting range of the chain adjusters (32mm) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters 4 can be rotated by 180. CAUTION ! ! ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

Chain maintenance

For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Motorex Chainlube Racing).
WARNING 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.

! WHEN

MOUNTING THE CHAIN POINT IN RUNNING DIRECTION.
CAUTION JOINT, THE CLOSED SIDE
OF THE SAFETY DEVICE MUST
Also check sprockets and chain guides for wear, and replace if necessary.

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 (10,70 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.

Checking the front brake pads
The brake pads can be inspected from below. The linings must be at least 1 mm (0,04 in) thick. AT WARNING
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 DONT PUT OFF HAVING YOUR BRAKE PADS CHANGED.
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 DESTROYING THE BRAKE DISC.
Changing the basic position of the brake pedal *
The basic setting of the foot brake pedal can be changed by turning the end stop roller 1. Using the push rod 2, the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). To keep the stop roller from turning while tightening, insert a hexagon wrench in bore A. ! IF CAUTION !
THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND THE BRAKE PADS BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES.

2 3-5mm

The reservoir for the rear disc brake is located on the left-hand side of the vehicle next to the carburetor carburetor connection boot. The brake fluid level may not drop below the MlN marking when the vehicle is in an upright position. WARNING 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 3. Then move the container outwards as indicated in the illustration. Remove plug 4 with rubber boot 5 and add brake fluid DOT 4 (Motorex Brake Fluid DOT 4) 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 DOT5 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

! DONT

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.
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 WARNING
CAUTION ! ! 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 DESTROYING THE BRAKE DISC.
Checking rear brake fluid level
Dismounting and mounting the front wheel
To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws 1 on the left fork leg. Then loosen the collar nuts 2 before loosening the clamp screws 3 on the right fork leg. Hold the front wheel and withdraw the wheel spindle 4. Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm ALLAN/IMBUS key while pulling. CAUTION ! ! DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED. ALWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT DAMAGING OF THE BRAKE DISC.
Before mounting, check if the left and the right 5 distance bushing are correctly positioned in the shaft seal rings. Extremely soiled distance bushings should be removed, cleaned and regreased. To mount the front wheel lift it into the fork and insert the brake disk into the brake caliper. Position the front wheel and mount the wheel spindle. Mount the collar nut 2, tighten the clamping sceews on the right side 3 to prevent the wheel spindle from turning and tighten the collar nut to 40 Nm (30 ft.lb). Loosen the clamping screews on the right side, Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs. Then tighten clamping screws 1 and 3 to a max. torque of 10 Nm (7 ft.lb). IF WARNING
YOU DONT 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 BEHAVIOR 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 rear wheel*
Jack the motorcycle up by frame so that the rear wheel no longer touches the ground. Loosen the collar nut 6, hold the rear wheel and pull out the wheel spindle 7 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. CAUTION ! ! DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED. 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 THERM 2000) TO PREVENT THE THREAD FROM JAMMING. ALWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT DAMAGING OF THE BRAKE DISC. NOTE: When removing the rear wheel always check the damping rubbers. The rear wheel is remounted in reverse order. Before tightening the collar nut to 80 Nm (59 ft.lbs), push the rear wheel forwards so that the chain tensioners lie on the tension screws. IF WARNING
YOU DONT 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 DRIVING 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 1 to the rear wheel. These 6 absorption rubbers wear with increasing operation time, and should be checked for wear whenever the rear wheel is dismounted. 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 CAUTION !
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.

max. 5 mm

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 youre getting ready to go anywhere on your motorcycle. WARNING IN ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE, ONLY KTMAPPROVED 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 Adventure (as of July 2002) BRIDGESTONE.TW 301/302 METZELER.ENDURO 3, ENDURO 4, KAROO MICHELIN.SIRAC, T63 PIRELLI.MT21, MT60, MT70, MT90

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 doesnt crank.
CAUSE Operating errror Discharged battery. Defect ignition lock or emergency OFF switch
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. Check ignition lock and emergency OFF switch, contact a KTM dealer. Replace fuse (3). Remove seat and replace the main fuse (1). If fuse blows again contact a KTM dealer. Recharge the battery and investigate the causes for discharging; contact a KTM dealer. Contact a KTM dealer. Contact a KTM dealer. Open fuel tap / emergency fuel tap, tank fuel, you did not use choke i.e. the warmstart device. Pay attention to starting off information (see driving instructions). 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. Pull the fuel hose from the fuel cock and allow the fuel to drain into a vessel if any fuel leaks out, check the fuel pump. If the fuel pump functions properly, clean the carburetor if no fuel leaks out, open the auxiliary fuel cocks and check for free passage or clean the fuel cock Disconnect the fuel hose at the carburetor. Put the end of the fuel hose into an appropriate container, open the fuel taps and start the engine. If fuel flows out, clean the carburetor. If no fuel flows out check the underpressure tube between the cylinder head and the fuel pump for leaks. contact a KTM dealer.
The engine doesn't crank. The neutral indicator lamp doesn't light up.
Blown fuse safe-starting system. Blown main fuse. Discharged battery.
The engine cranks only with pulled clutch lever Engine cranks engaged. with gear
Defect safe-starting system. Defect safe-starting system. Operating error
Engine cranks but doesnt start.
The motorcycle has been out of operation for a longer period of time. Therefore old fuel has accumulated in the float chamber

Fuel supply interrupted

Defective fuel pump
Flooded engine Sooty or wet spark plug Electrode gap too large

Fully open the throttle when starting or exchange the spark plug, respectively Clean and dry the spark plug or exchange it, respectively Adjust spark plug elektrode gap to 0,9 mm
TROUBLE Engine cranks but doesnt start.
CAUSE Spark plug connector or spark plug faulty
REMEDY 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 Remove the seat, the right side cover and the fuel tank. Clean the plug connection and treat it with contact spray Dismount and clean carburetor Check if carburetor is fitted in correctly Disassemble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Dismount carburetor and check if worn out Replace float needle Replace float Adjust choke cable.
The plug connection of the CDIunit, the pulse generator or the ignition coil has oxydized
Water in carburetor or jets blocked Carburetor does not fit in properly at intake flange Engine fails to idle Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Engine does not rev high Carburetor fuel level too high because Float needle is dirty or worn out Float leaks The cold starting system is permanently activated due to a lack of play in the choke cable. Defective membrane of slide Carburetor leaking Loose carburettor jets Electronic ignition timing faulty Engine will not reach full power Fuel supply partically interrupted or carburetor dirty Float leaks Defective membrane of slide Carburetor leaking Air filter very dirty Valve clearance to small Loss of compression because hand decompressor has no play Electronic ignition timing faulty
Replace membrane Check vacuum hose and venting hose of carburetor for correct position (no kinks) Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor Have fuel pump checked. Replace the float Replace membrane Check vacuum hose and venting hose of carburetor for correct position (no kinks) Clean or replace air filter, contact a KTM dealer Have valve clearance adjusted Check setting of the hand decompression cable Have ignition system checked

STANDARD ADJUSTMENT - FORK
WP 4860 MXMA 1418X14 4,4 N/mm 4 mm 120 mm ca 420 ccm SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
WP BAVP3612 0118X7 70/mm (0,9 in)
Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil
Compression adjuster Rebound adjuster Spring Spring preload
TIGHTENING TORQUES - CHASSIS 640 LC4 ADVENTURE
Collar nut front axle Collar nut rear axle Shock absorber top/bottom Collar screws brake disk front/rear Screw brake caliper front Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Sprocket screws on nuts Collar nut swingarm bolt Clamping screws top triple clamp (MXMA 4860) Clamping screws bottom triple clamp (MXMA 4860) Clamping screws fork stubs Spoke nipple Other screws on chassis M16x1,5 M20x1,5 M10 M6 (10,9) M8 M12 M14x1,5 M10 M8 M14x1,5 M8 M8 M8 M4 M6 M8 M10 M6 M8 MNm 80 Nm 45 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm 60 Nm 100 Nm 45 Nm Loctite 243 + 35 Nm 100 Nm 20 Nm 15 Nm 10 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm (30ft.lb) (59ft.lb) (33ft.lb) (7ft.lb) (19ft.lb) (44ft.lb) (74ft.lb) (33ft.lb) (25ft.lb) (74ft.lb) (15ft.lb) (11ft.lb) (7ft.lb) (3ft.lb) (7ft.lb) (19ft.lb) (33ft.lb) (11ft.lb) (22ft.lb) (37ft.lb)
Other colllar nuts an chassis

HEAD WORD INDEX

Page Serial number locations..5 Chassis number...5 Engine number, engine type..5 Operation instruments..5 Clutch lever...5 Hand decompression lever..5 Hand brake lever..6 Choke lever...6 Ignition lock with 3 switch positions..6 Multi-functional digital speedometer.7 Setting options in the display..8 Indicator lamps...9 Tachometer...9 Combination switch..10 Starter tip switch, emergency OFF switch, light switch.10 Filler cap....10 Fuel taps....10 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 Baggage carrier..12 General tips and warnings for starting the motorcycle.14 Instructions for initial operation..14 Running in...14 Driving instructions...15 Check the following before each start..15 Starting when the engine is cold...16 Starting when the engine is waorm or hot..16 What to do when the engine is flooded..16 Kickstart instructions...17 Starting off...17 Shifting, Riding..17 Braking...17 Stopping and parking...18 Refueling...18 Periodic maintenance-schedule..20 Maintenance work on chassis and engine..22 Tool set...22 Removing the seat..22 Checking and adjusting steering head bearing..23 Bleeder screws front fork...23 Cleaning the dust sleeves of the telescopic fork.23 Changing the spring preload of the shock absorber.24 Checking rubber ring on the WP rear shock ansorber..24 Lubricate shock absorber linkage...24 Checking chain tension..25 Page Correct chain tension...25 Chain maintenance...26 Chain wear...26 General information about KTM disc brakes.27 Adjusting of free travel at the hand brake lever.28 Checking of brake fluid level - front brake.28 Refilling the front brake fluid reservoir..28 Checking the front brake pads..28 Changing the basic position of the foot brake pedal.29 Check the rear brake fluid level..29 Refilling the rear brake fluid reservoir..29 Checking the rear brake pads...29 Dismounting and mounting the front wheel.30 Dismounting and mounting the rear wheel..30 Checking the shock absorbtion rubbers in the rear hub.31 Tires, air pressure...31 Checking spoke tension..32 Socket for electric accessories...32 Battery...33 Charging the battery...33 Fuses...34 Removing and mounting the headlight mask..34 Replacing the headlight bulb..34 Exchanging the brake light and tail light blub..35 Removing the tank..35 Cooling system..36 Checking the cooling liquid level...36 Cleaning the air filter...37 Adjusting the throttle cable..38 Checking the oil level of the hydraulic clutch..38 Changing the orginal position of the clutch lever.38 Adjusting the choke cable play..39 Checking the adjustment of the hand decompression cable 39 Adjusting idling speed..39 Draining of float chamber of the carburetor.40 Engine oil...40 Checking the engine oil level..40 Oil circuit...41 Oil and fine screen filter change, bleeding of the oil system 41 Changing oil filter..42 Trouble shooting...43 Cleaning....46 Conservation for winter operation..46 Storage...46 Re-initation after time of storage..46 Technical specifications - engine..48 Technical specifications - chassis..50 Head word index...52 Wiring diagram..appendix

FUELRECOMMENDATIONSKTM4STRMODELS
From model year 2000 Status January 2011
250 SX-F 250 SXS-F 250 SX-F 250 EXC RACING 250 EXC-G RACING 250 EXC RACING SIX DAYS 250 EXC-F (SIX DAYS) 250 EXC-F Champions Edition 250 XCF-W 250 XC-F 250 XCF-W Champions Edition 350 EXC FACTORY RACING 350 SX-F 350 XC-F 400 EXC RACING 400 EXC 400 EXC-G RACING 400 EXC RACING SIX DAYS 400 EXC FACTORY RACING 400 MXC RACING 400 LC4-E 400 LC4-E Mil Bronze 400 LS-E/Mil 400 SC 400 SXC 400 SX RACING 400 XC-W 450 XC-G RACING 450 XC CROSS COUNTRY 450 MXC-G RACING 450 EXC RACING 450 EXC RACING SIX DAYS 450 EXC FACTORY RACING 450 EXC-G RACING 450 EXC-R (SIX DAYS) 450 EXC (SIX DAYS) 450 EXC Champions Edition 450 Rally Factory 450 SX-(F) 450 SXS-(F) 450 XC + XC-W 450 XC-F 450 XC-W Champions Edition 450 XC-W (SIX DAYS) 450 SMR 450 SMS

model year

2006-2011 2006-2002-2006 2004-2005 2002-2003 2007-2007-2011 2007-2011 2000-2007 2009-2011 2002/04-06 2001-2001-2000-2003-2005 2003-2007 2003-2003-2009-2003-2011 2003-2008-2008-2011 2004-2010 2004
RON 80-90 RON 91 PON 77-86.6 PON 87.6

RON 95 PON 91

RON 98 PON 94

Comment: after setting the ignition curve for low-octane fuel Notes on fuel quality (for all models) Page 6
505 SX(S)-F 505 XC-F 520 MXC RACING 520 EXC RACING 520 EXC RACING SIX-DAYS 520 EXC-G RACING 520 SX RACING 525 XC-G RACING 525 XC DESERT RACING 525 XC + XC-W 525 MXC DESERT RACING 525 MXC-G RACING 525 EXC RACING 525 EXC FACTORY RACING 525 EXC RACING SIX-DAYS 525 EXC-G RACING 525 SX RACING 525 SX SUPERMOTO 525 SMR 530 EXC-R (SIX-DAYS) 530 EXC (SIX DAYS) 530 EXC Champions Edition 530 XCR-W 530 XC-W (SIX DAYS) 540 SXS RACING 560 SMR
2007-2008 2008-2009 2001-2002 2000-2002 2001-2000-2002 2005-2006 2005-2003-2005 2003-2005 2003-2003-2007 2003-2006 2003-2006 2004-2005 2004-2009-2008 2009-2011 2000-2006 2006-2007

RON 95 PON 91

450 XC ATV 525 XC ATV 450 SX ATV 525 SX ATV
2008-2009 2008-2011 2009-2010 2009-2010

RON 95 PON 91

model 125 DUKE 620 LC4 SUPERCOMPETITION 620 SC SUPERMOTO 625 SXC 625 SMC 625 SUPERCOMPETITION 625 SC SUPERMOTO 640 LC4 ENDURO 640 LC4 ENDURO 640 LC4 SUPERMOTO 640 LC4 SUPERMOTO 640 LC4 ADVENTURE 640 LC4 ADVENTURE 640 DUKE II 640 DUKE II 650 RALLY 660 RALLY 660 SMC 660 SMS 660 SUPERMOTO FACTORY 690 SUPERMOTO (Limited Edition) 690 SUPERMOTO PRESTIGE 690 SUPERMOTO R 690 RALLY 690 ENDURO / R 690 SMC 690 DUKE / R 950 ADVENTURE 950 ADVENTURE S 950 SUPER ENDURO ( R ) 950 SUPERMOTO 950 SUPERMOTO R 990 SUPERMOTO 990 SUPERMOTO R 990 SUPERMOTO T 990 SUPER DUKE ( R ) 990 ADVENTURE R 990 ADVENTURE ABS 990 ADVENTURE S 990 AVENTURE DAKAR 1190 RCRC8 TRACK 1190 RC8 R 1190 RC8 R Model year 2011 2000-2001 2000-2001 2003-2007 2004-2002 2000-2003 2004-2006 2000-2003 2004-2006 2000-2003 2004-2007 2000-2003 2004-2000-2006 2003-2002-2003 2007-2008-2009 2007-2010 2008-2011 2008-2011 2008-2011 2003-2005 2003-2005 2006-2009 2005-2007 2006-2008 2008-2009 2009-2011 2009-2011 2005-2011 2009-2011 2006-2010 2006-2008-2009-RON 80-90 PON 77-86.6 RON 91 PON 87.6 RON 95 PON 91 RON 98 PON 94 RON 100 PON 95.8
FUELRECOMMENDATIONSKTM2STRMODELS
50 SENIOR ADVENTURE 50 SENIOR ADVENTURE 50 JUNIOR ADVENTURE 50 MINI ADVENTURE 50 SX PRO SENIOR LC 50 SX PRO JUNIOR LC 50 SX SENIOR 50 SX JUNIOR 50 SX JUNIOR 50 SX 50 SUPERMOTO 60 SX 65 SX 65 SX 65 XC 85 SX 85 SX 85 XC 105 SX 105 SX 105 XC 125 EXC 125 EXC 125 EXC Champions Edition 125 EXC SIX DAYS 125 EXC SIX DAYS 125 SX 125 SX 125 SXS 125 SXS 144 SX 150 SX / XC 200 MXC 200 EXC 200 EXC / XC-W 200 EXC-GS 200 EXC SGP GS
2000-2005 2006-2007 2000-2003 2000-2002 2002-2005 2002-2005 2000-2001 2000-2001 2006-2009 2006-2000 2000-2005 2006-2011 2008-2009 2003-2008-2009 2004-2009 2000-2007 2008-2001-2007 2008-2011 2000-2007 2008-2011 2000-2002 2003-2009 2007-2008 2009-2011 2000-2003 2000-2007 2008-2011 2000-2002 2000-2002

RON 95 PON 91 1:40-1:60

RON 95 PON 91 1:40

RON 95 PON 91 1:60

RON 98 PON 94 1:40

RON 98 PON 94 1:60

Anmerkung: unleaded fuel with at least RON xx or PON yy, mixed with high grade two stroke oil (Motorex Cross Power 2str.) at the assigned mixture ratio (e.g.: 1:40). Notes on fuel quality (for all models) Page 6
200 XC 200 XC 200 XC-W 200 XC-W 200 SX 250 EXC 250 EXC 250 EXC SIX DAYS 250 EXC SIX DAYS 250 EXC FACTORY 250 MXC 250 XC 250 XC 250 XC-W 250 XC-W 250 SX 250 SX 250 SXS 250 SXS 250 SXS 300 EXC 300 EXC (E) 300 EXC SIX DAYS 300 EXC (E) SIX DAYS 300 XC 300 XC 300 XC-W 300 XC-W 300 MXC 380 EXC 380 MXC 380 SX
2006-2007 2008-2009 2006-2007 2008-2011 2003-2004 2000-2007 2008-2011 2001-2007 2008-2000-2005 2006-2007 2008-2011 2006-2007 2008-2011 2000-2007 2008-2011 2000-2001 2003-2004 2005-2008 2000-2007 2008-2011 2001-2007 2008-2011 2006-2006-2007 2008-2011 2000-2005 2000-2002 2000-2002 2000-2002

MODELS WITH SEPARATE LUBRICATION
50 MINI ADVENTURE 50 SX MINI 125 EXE EXE SUPERMOTO SUPERMOTO 80
2003-2008 2009-2011 2000-2001 2000-2001 2000-2001 2000-2001

RON 91 PON 87.6

RON 95 PON 91
NOTES ON FUEL QUALITY (for all models)
Only use lead-free fuel that is in compliance with the EN 228 standard with the corresponding octane
number (RON.) or is equivalent to these specifications.
It is safe to use fuel with up to 10 % ethanol (E10 fuel). Do not use fuel made from methanol (e. g. M15, M85, M100) or fuel with more than 10 % ethanol (e. g.

E15, E25, E85, E100).