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ENGLISH

23

Dismounting and mounting the rear wheel (LC4)

Park the motorcycle on the center stand. The rear wheel must not touch 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.

!

CAUTION

!

– D

O NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED

.

– A

LWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINTING

UPWARDS

. O

THERWISE THE BRAKE DISC MAY BE DAMAGED

.

– I

F THE AXLE IS DISMOUNTED

CLEAN THE THREAD OF THE WHEEL SPINDLE AND

COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE

(S

HELL

A

DVANCE

G

REASE

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 (60 ft.lb), push the rear wheel forwards so that the chain 
tensioners lie on the tension screws.

Dismounting and mounting the rear wheel (LC4 SUPERMOTO)*

To remove the front wheel, jack the motorcycle up on its frame so that the
front wheel no longer touches the ground.
Remove rear screw 

4

from the chain guard.

To avoid damage to the rim and to fix the brake caliper, stretch a rubber
band or an old hose between the brake caliper and the side stand (see
illustration).
Remove collar nut 

1

, remove chain tensioner 

2

, hold on to the rear wheel

while you pull out wheel spindle 

3

.

Push the rear wheel as far forward as possible and remove the chain from
the sprocket. Carefully push the rear wheel back, lift slightly and swivel to
the left. Carefully lift the wheel diagonally towards the rear and remove
from the swing arm. Do not use force to remove the rear wheel to avoid
damaging the rim.

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 (60 ft.lb), push the rear wheel forwards so that the chain 
tensioners lie on the tension screws.

WARNING

– I

F 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 DRIVING BEHAVIOR

OF YOUR MOTORCYCLE

.

– A

FTER MOUNTING THE REAR WHEEL

KEEP OPERATING THE FOOTBRAKE UNTIL THE

PRESSURE POINT RETURNS

.

– I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE

OTHER

-

WISE 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 

5

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.

!

CAUTION

!

I

F THE SHOCK ABSORPTION RUBBERS ARE NOT REPLACED IN GOOD TIME

THE REAR

SPROCKET CARRIER AND THE REAR HUB WILL BE DAMAGED

. A

LLWAYS REPLACE ALL

ABSORPTION RUBBERS

NEVER SINGLE RUBBERS

.

max. 5 mm

1

2

3

4

5

Summary of Contents for 640 LC4 2002

Page 1: ...OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art Nr 3 210 21 9 2001 640 LC4 640 LC4 SUPERMOTO...

Page 2: ...by any person other than for purposes of mainten ance 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...

Page 3: ...of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorc...

Page 4: ...osition of the foot brake pedal 20 Page Check the rear brake fluid level 21 Refilling the rear brake fluid reservoir 21 Checking the rear brake pads 21 Dismounting and mounting the front wheel LC4 22...

Page 5: ...UTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS 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 starte...

Page 6: ...The green indicator lamp lights up when the gear is switched to idle The blue indicator lamp lights up when the high beam is on The red cooling liquid temperature warning lamp lights up at a cooling...

Page 7: ...pted Filler cap The filler cap 7 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 T...

Page 8: ...d second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled WARNING WHEN STARTING THE ENGINE MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING...

Page 9: ...t will go turn it back counter clockwise by as many clicks as are specified for the relevant type of fork WP 0518W714 12 Klicks 640 LC4 WP 0518W722 14 Klicks 640 LC4 Supermoto Compression damping of s...

Page 10: ...afety 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 pre...

Page 11: ...ch is on Check if the ignition is on the headlight is on ignition lock in position If this is not the case the battery is discharged If the lights are on proceed as described in the Trouble shooting s...

Page 12: ...ET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY OF TIME WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOR...

Page 13: ...N PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS NOTE REGARDING THE CENTER STAND We advise the following procedure to place the motorcycle on the center stand as effortlessl...

Page 14: ...ENGLISH 13...

Page 15: ...asher 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 disc...

Page 16: ...vals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check al...

Page 17: ...G 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 I...

Page 18: ...gs should be greased 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...

Page 19: ...TURE 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...

Page 20: ...D 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 br...

Page 21: ...Y 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...

Page 22: ...ND 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...

Page 23: ...ve runs upwards and parallel to the fork leg see below Tighten the clamp screws 2on the right fork leg so as to prevent the wheel spindle from twisting and then tighten the collar nuts with 40 Nm Loos...

Page 24: ...ft slightly and swivel to the left Carefully lift the wheel diagonally towards the rear and remove from the swing arm Do not use force to remove the rear wheel to avoid damaging the rim NOTE If the re...

Page 25: ...e recommend replacing tires at the latest when the tread is down to 2 mm Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life...

Page 26: ...E DO NOT REMOVE THE LOCKING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR BATTERY STORAGE When preparing the motorcycle for a longer period o...

Page 27: ...DER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Exchanging the headlight lamp Remove...

Page 28: ...EED 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 COOLI...

Page 29: ...from TWIN AIR 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 high grade filter oil rubbing to coat the entire filter...

Page 30: ...o 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 4 that...

Page 31: ...need be made to the automatic decompressor Engine oil Only use fully synthetic branded oils Shell Advance Ultra 4 meeting or sur passing the quality requirements of API classes SG or SH see specificat...

Page 32: ...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 auth...

Page 33: ...herwise engine oil would get into the air filter box by way of the engine venting system Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGIN...

Page 34: ...t a KTM dealer Replace fuse below the headlight mask Remove seat and replace the main fuse If fuse blows again contact a KTM dealer Contact a KTM dealer Contact a KTM dealer Open fuel tap tank fuel yo...

Page 35: ...emble 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...

Page 36: ...t been switched off The battery isn t charged by the generator because REMEDY Readjust or replace ventilation hose Check engine oil level when the engine is warm correct if necessary Use thicker engi...

Page 37: ...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 ca...

Page 38: ...6 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d instrument lights 12V 1 2W socket W2x4 6d indicator lamps 12V 1 2W socket W2x4 6d br...

Page 39: ...ite 243 35 Nm 25ft lb Collar nut swingarm bolt M14x1 5 100 Nm 74ft lb Clamping screws top triple clamp USD 43 M8 20 Nm 15ft lb Clamping screws bottom triple clamp USD 43 M8 15 Nm 11ft lb Clamping scre...

Page 40: ...iters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5t...

Page 41: ...oval 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 c...

Page 42: ...E SHOCK MAY BE DAMAGED REFER TO THE OWNERS MANUAL K T M 6 4 0 L C 4 6 4 0 L C 4 S u p e r m o t o 2 0 0 2 THIS KTM EXHAUST SYSTEM 583 05 083 200 MEETS EPA NOISE EMISSION REQUIREMENTS OF 80 dBA FOR MOD...

Page 43: ...ENGLISH 42 K T M 6 4 0 L C 4 6 4 0 L C 4 S u p e r m o t o 2 0 0 2...

Page 44: ...SA only 40 Cooling system 27 Correct chain tension 18 Dismounting and mounting the front wheel 22 Dismounting and mounting the rear wheel 23 Draining the carburetor float chamber 29 Driving Instructio...

Page 45: ......

Page 46: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321021...

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