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KTM 640 LC4 2002, Owner'S Manual, Page: 38 / 46

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KTM 640 LC4 2002 Owner'S Manual Download Page 38

ENGLISH

37

TECHNICAL SPECIFICATIONS - CHASSIS   640 LC4,  640 LC4  SUPERMOTO  2002

640 LC4

640 LC4 Supermoto

Frame

Central chrome-moly-steel frame

Fork

W

hite 

P

ower – 

U

p 

S

ide 

D

own 4357 MXMA

Wheel travel front/rear

270 / 300 mm  (10,6 / 11.8 in)

Rear suspension

Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing

Front brake

Disc brake with carbon-steel brake disc, brake caliper floated

Front brake disc

Ø 300 mm (11.8 in)  

Ø 320 mm (12.6 in)

Rear brake

Disc brake with carbon-steel brake disc 

 

220 mm (8.7 in), brake caliper floated

Tyres front

90/90-21

120/70-17

Air press. road, driver only

1.8 bar (26 psi)

2.0 bar (29 psi)

Air press. road with passenger

2.0 bar (29 psi)

2.2 bar (31 psi)

Tyres rear

140/80-18

160/60-17

Air press. road, driver only

2.0 bar (29 psi)

2.2 bar (31 psi)

Air press. road with passenger

2.2 bar (31 psi)

2.4 bar (34 psi)

Fuel tank capacity

11 or 18 liter (2.9 or 4.8 US gallons),   2.5 liter (0,6 US gallons) reserve

Final drive ratio

16:42t

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)
brake – rear light   . . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light   . . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination   . . . 12V 5W (socket W2,1x9,5 d)

Battery

maintenance-free battery   12V  8Ah

Steering angle

62,5 °

63°

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat high

940 mm (37.6 in)

910 mm (36.4 in)

Ground clearance

355 mm (14.0 in)

335 mm (13.2 in)

Dead weight without fuel

136kg (300 lbs)

137 kg (302 Ibs)

Max. permissible front axle load

211 kg (465 lbs)

Max. permissible rear axle load

335 kg (740 lbs)

Max. permissible laden weight

350 kg (773 lbs)

640 LC4

640 LC4

SUPERMOTO

WP 0518W714

WP 0518W722

Compression adjuster

20

14

Rebound adjuster

12

14

Spring

4,2 N/mm

5,0 N/mm

Spring preload

6 mm (0,24in)

9 mm (0,36in)

Air chamber length

150 mm (5,9in)

130 mm (5,1in)

Fork oil

SAE 5

SAE 5

STANDARD ADJUSTMENT - FORK

640 LC4

640 LC4

SUPERMOTO

WP 0118W724

WP 0118W721

Compression adjuster

3

5

Rebound adjuster

7

7

Spring

66 / 260

75 / 260

Spring preload

23,5 mm(0,94in)

15 mm(0,6in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

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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