KTM 640 LC4 Adventure Owner'S Manual Download Page 1

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BEDIENUNGSANLEITUNG

2004

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART.NR: 3.210.86

640 LC4 ADVENTURE

BEDIENUNGSANLEITUNG

2004

Summary of Contents for 640 LC4 Adventure

Page 1: ...BEDIENUNGSANLEITUNG2004 OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 210 86 640 LC4 ADVENTURE BEDIENUNGSANLEITUNG2004 ...

Page 2: ...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 ...

Page 3: ...s 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 ...

Page 4: ...n 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 consequen...

Page 5: ...er ring on the WP rear shock absorber 24 Lubricating the shock absorber linkage 24 Page Checking chain tension 25 Correct chain tension 25 Chain maintenance 26 Chain wear 26 General informations 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 Chang...

Page 6: ...he original position of the clutch lever see maintenance work on chassis and engine 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 ...

Page 7: ...ns of ignition lock 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 all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Socket for electric accessories A socket is...

Page 8: ...ize the CLOCK 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 sho...

Page 9: ...he 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 0...

Page 10: ... 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 light will light up when the cooling liquid has ...

Page 11: ...gnition circuit and starter circuit are switched on The engine cannot be started in position ignition circuit and starter circuit are interrupted 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 To close the tank insert the filler cap turn the ignition ke...

Page 12: ...turn the twist grip back to the ON position so that you will have backup fuel next time too NOTE The fuel tap must be open during operation The fuel tap must be closed for parking 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 Kickstarter The kickstarter ...

Page 13: ...sing 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 1418Y753 14 clicks Compression damping of shock absorber With...

Page 14: ...ENGLISH 13 1 2 2 3 Baggage carrier Grips The baggage carrier may be loaded with up to 10 kg The two lateral hoops serve as handles for the passenger Footrests The passenger footrests 3 fold up ...

Page 15: ... Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet Pay attention to running in instructions 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...

Page 16: ...igned 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 ...

Page 17: ...rged 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 Tr...

Page 18: ...CREASED TEAR OF BRAKE PADS AND BRAKE DISCS 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 WARNING IF 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 KICKSTART...

Page 19: ...ot 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 CAUTION THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE STAND YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME A...

Page 20: ...ehicle next to the CDI 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 CAUTION IF FUEL HAVING ...

Page 21: ...t 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 suspensio...

Page 22: ...bricate 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 Treat exposed metal components except for the braking and exhaust systems with wax based anti corrosion agents Treat ign...

Page 23: ...OPERLY DISPOSE OF OIL GREASE FILTERS FUEL CLEANSERS BRAKE FLUID COOLING LIQUID ETC OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY ALSO OBSERVE THE SAFETY REGULATIONS WHEN HANDLING THESE SUBSTANCES 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 UNFASTEN SELF LOCKING NUTS YOU HAVE TO RE...

Page 24: ...few turns to let overpressure if any escape from the interior 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 CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF YOUR FORK IS ...

Page 25: ...nted 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 REPLA...

Page 26: ...COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE 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 whe...

Page 27: ...NT THE CLOSED SIDE OF THE SAFETY DEVICE MUST POINT IN RUNNING DIRECTION 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 s...

Page 28: ...HOES IF YOU USE DIFFERENT BRAKE SHOES THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAFFIC 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 br...

Page 29: ...rvoir Loosen screws 2 and remove lid 3 and membrane 4 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 4 Motorex Brake Fluid DOT 4 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR S...

Page 30: ...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 mak...

Page 31: ...eel against the brake disks according to the direction of travel see arrow B To mount the front wheel lift the wheel into the fork slightly pull one brake caliper out and push the tire in between the brake calipers Insert the brake disks in the brake calipers and mount the axle passage Mount the collar screw 1 and tighten slightly Tighten the clamp screws 2 on the right fork leg axle passage in th...

Page 32: ... 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 L...

Page 33: ... 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 PROPERL...

Page 34: ...paring 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 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 chec...

Page 35: ... THE WHOLE ELECTRICAL INSTALLATION Removing and mounting the headlight mask The headlight mask must be removed to replace the headlight lamps the indicator lamps or the tachometer lamps REMOVING THE HEADLIGHT MASK Use the wrench from the tool kit to remove the 6 screws 1 of the headlight mask Swing the headlight mask forward disconnect the flasher cables and remove the mask MOUNTING THE HEADLIGHT ...

Page 36: ...4 Close the auxiliary fuel cocks turn in a clockwise direction and the fuel cock OFF position Close the fuel lines to the 3 fuel cocks Unplug the plug connector 3 to the gasoline level sensor CAUTION THE GASOLINE LEVEL SENSOR WILL BE DAMAGED IF THE PLUG CONNECTOR 3 IS NOT UNPLUGGED WHEN YOU REMOVE THE TANK Remove the collar nut 4 and washers Lift the rear tank 10 12 cm and lift off Mount the tank ...

Page 37: ...ON 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 temperature is 98 C 208 4 F and the igniti...

Page 38: ...ter 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 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 positi...

Page 39: ...e 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM workshop CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Adjusting the throttle cable When starting to turn the throttl...

Page 40: ...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 10 mm 0 39 in until resistance is felt the exhaust valves begin to open To adjust move back the protective cover 4 loosen the counter nut 5 and correct the adjusting screw 6 accordingly Tighten counter nut and push back prot...

Page 41: ...otorcycles 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 ...

Page 42: ...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 WARNING AN ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT IS VERY HOT DO NOT BURN YOURSELF...

Page 43: ... the engine and mount the plug together with the gasket and tighten to 25Nm Allow the engine to warm up check the engine oil level and correct if necessary Afterwards check the entire oil system for leakage Mount the engine guard 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...

Page 44: ...authorized workshop Check the ignition and the emergency OFF switch visit an authorized workshop Replace the fuse 3 Remove the seat and replace the main fuse 1 if it blows again visit an authorized workshop Charge the battery and determine the cause of discharging visit an authorized workshop Visit an authorized workshop Visit an authorized workshop Open the fuel tap or auxiliary fuel tap refuel d...

Page 45: ...g to the ground bright area on the engine and start a strong spark should be visible at the spark plug if no spark is visible replace the spark plug if no spark is visible yet disconnect the spark plug cap from the ignition wire hold approx 5 mm away from the ground and start if a spark is visible now replace the spark plug connector if no spark is visible have the ignition system checked Remove t...

Page 46: ...oling liquid use a brand name antifreeze Shorten or replace the radiator hose Remove the thermostat and have it checked or replaced opening temperature 70 C visit an authorized workshop Replace the fuse and check the fan for proper functioning see below Visit an authorized workshop Check the fan for proper functioning To check start the engine and short circuit the connections on the thermoswitch ...

Page 47: ...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...

Page 48: ...ENGLISH 47 ...

Page 49: ...ssion ring 1 taper face ring 1 oil scraper ring Engine lubrication 2 Eaton Oilpumps Quantity of engine oil see table Engine oil 2 1 liters including frame Primary ratio straight geared spur wheels 31 79 teeth Clutch multi disc clutch in oil bath hydraulically operated Transmission 5 speed claw shifted Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition ti...

Page 50: ... head top sect M6x50 M6x55 12 9 15 Nm 11ft lb Cylinder head screws M10 50 Nm 37ft lb Collar nuts at cylinder base M10 40 Nm 30ft lb Hexagon screw chain sprocket M10 10 9 Loctite 243 60 Nm 44ft lb Oil drain plug M22x1 5 30 Nm 22ft lb Magnetic plug M12x1 5 20 Nm 15ft lb Plug bypass valve M12x1 5 20 Nm 15ft lb Hollow screws oil lines M8x1 10 Nm 7ft lb Hollow screws oil lines M10x1 15 Nm 11ft lb Jet s...

Page 51: ...iter 0 9 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Lampenbestückung head light H1 12V 55W Sockel P14 5S parking light 12V 2W Sockel Ba9s brake rear light 12V 21 5W Sockel BaY15d flasher light 12V 10W Sockel Ba15s license plate illintion 12V 5W Sockel W2 1x9 5d Battery maintenance free battery 12V 8Ah Steering angle 62 5 Wheel base 1510 10 mm 59 4 0 4 in Seat high 945 mm 37 ...

Page 52: ...ing screw M10 45 Nm 33ft lb Sprocket screws on nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swingarm bolt M14x1 5 100 Nm 74ft lb Clamping screws top triple clamp MXMA 4860 M8 20 Nm 15ft lb Clamping screws bottom triple clamp MXMA 4860 M8 15 Nm 11ft lb Clamping screws fork stubs M8 10 Nm 7ft lb Bleeder screw oil reservoir frame M16x1 5 25 Nm 19ft lb Spoke nipple M4 4 Nm 3ft lb Other screws on chass...

Page 53: ...nt wheel 30 Dismounting and mounting the rear wheel 31 Display 7 Draining of float chamber of the carburetor 40 Driving instructions 15 Engine number engine type 5 Engine oil 40 Exchanging the brake light and tail light bulb 35 Page Filler cap 10 Foot brake pedal 11 Footrests 13 Fuel taps 10 Fuses 34 General informations about KTM disc brakes 27 General tips and warnings for starting the motorcycl...

Page 54: ...ANHANG APPENDICE APPENDIX APÉNDICE 1 ...

Page 55: ...ANHANG APPENDICE APPENDIX APÉNDICE 2 ...

Page 56: ...nsdigitaltacho Tachimetro digitale multifunzione Neutral switch Leerlaufschalter Interruttore folle Octane selector Oktananpassung Adattamento anticipo agli ottano Pick up Impulsgeber Pick up Rear brake switch hinterer Bremslichtschalter Interruttore luce post di stop Rear light brakelight hinteres Begrenzungslicht Bremslicht Luce post di posizione stop Regulator rectifier Regelgleichrichter Regol...

Page 57: ...ANHANG APPENDICE APPENDIX APÉNDICE 4 ...

Page 58: ...dometer Ordinateur de bord Velocímetro digital multifuncional Neutral switch Contacteur de point mort Interruptor de ralentí Octane selector Sélection pour l indice d octane Ajuste de octano Pick up Capteur d allumage Generador de impulsos Rear brake switch Contacteur de frein arrière Interruptor de luz del freno trasero Rear light brakelight Feu rouge stop Luces de parqueo traseras luces de freno...

Page 59: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 11 2003 FOTO MITTERBAUER ...

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