Vehicle Segment:
Performance Dual-Sport, Supermoto, and Enduro Motorcycles
Brand Philosophy:
KTM's 'Ready to Race' philosophy is evident in the LC4 line, demanding precise maintenance and repair for optimal performance.
Competitors Era:
Competed against other European and Japanese performance off-road and street-legal motorcycles of its time.
Engine Type:
Robust single-cylinder 'LC4' engine, known for its torque and versatility.
Model Diversity:
The LC4 platform was adapted for various disciplines: Adventure (640 Adventure), Motocross/Enduro (SXC, EXC variants), and Supermoto (SC, SMC variants).
Completeness:
100% complete and intact, ensuring no missing or corrupt pages.
Accessibility:
Instant download, easy to use, printable for hands-on work.
Primary Coverage:
Workshop Repair and Service
Model Variations Covered:
400LC4, 400LC4-E, 400SC, 400SX, 400SXC, 540SXC, 620LC4 COMPETITION, 620SC, 620SC SUPERMOTO, 620SX, 625SC, 625SC SUPERMOTO, 625SMC, 625SXC, 625SXC EUR/USA, 640 ADVENTURE-R, 640 DUKE, 640 DUKE AUS/USA, 640 DUKE-E, 640LC4, 640LC4 ADVENTURE, 640LC4 SUPERMOTO, 640LC4-E, 640LC4-E SUPERMOTO, 640 SUPERMOTO, 660RALLY, 660SMC
Estimated Page Count:
Highly comprehensive (exact count not provided, but extensive based on sectional listings)
Type:
Workshop Repair Service Manual
Language:
English (presumed based on product description)
Digital Format:
PDF (Downloadable)
Engine:
Engine specifications, diagnostics, repair, rebuild, maintenance for all LC4 engine variants (400cc, 540cc, 600cc, 620cc, 625cc, 640cc, 660cc)
Chassis:
Chassis components, suspension, steering, frame, wheels, brakes, bodywork
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, starter system, electronic components
Fuel System:
Carburetor/fuel injection systems, fuel pump, fuel tank, fuel lines
Cooling System:
Radiator, coolant, water pump, thermostat (where applicable)
Exhaust System:
Exhaust pipes, mufflers, emissions controls
Maintenance:
Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding guides
Repair:
Detailed step-by-step repair instructions for all major and minor components, including engine teardown and reassembly
Rebuilding Refurbishment:
Comprehensive guidance for engine and component rebuilds, refurbishment of worn parts
Restoration:
Guidance applicable to restoring older models within the specified year range
Depth:
Professional Technician and Mechanic Level - A-Z coverage
Detail Level:
Extremely detailed, covering all diagnostic and repair procedures
Illustrations:
High-quality photos, illustrations, and diagrams included
Engine Type:
Four-stroke, single-cylinder, liquid-cooled (most variants), SOHC/DOHC (depending on specific model)
Typical Horsepower Range:
Varies significantly by model and year, generally from ~40 HP (400cc) to ~50-60 HP (600cc+ variants).
Typical Torque Characteristics:
Known for strong mid-range torque, characteristic of larger single-cylinder engines.
Carburetion:
Primarily Mikuni (e.g., TM40, BST40) or Keihin carburetors. Some later models may feature fuel injection.
Oil Type:
High-quality motorcycle-specific 4-stroke engine oil (e.g., JASO MA certified) with appropriate viscosity (e.g., 10W-40, 15W-50 depending on ambient temperature).
Valve Clearance Intervals:
Typically requires checking/adjustment every 5,000-10,000 km (3,000-6,000 miles), specific values detailed in the manual.
Transmission Type:
5-speed or 6-speed sequential manual gearbox
Optional Transmissions:
N/A (standard for the platform)
Clutch Type:
Hydraulically operated multi-plate wet clutch
Transmission Oil Type:
Engine oil is typically used in the shared lubrication system. Refer to manual for exact grade and capacity.
Safety Standards:
Designed to meet relevant road legal and off-road safety standards for motorcycles of the era.
Braking System:
Hydraulic disc brakes front and rear, often with Brembo components on higher-spec models.
Suspension:
High-quality WP suspension (forks and rear shock) with adjustable damping and pre-load, crucial for control and safety.
Frame Construction:
Strong steel trellis frame providing rigidity and rider feedback.
Oil Change Interval:
Typically every 3,000-5,000 km (2,000-3,000 miles) or annually, depending on usage conditions. Specifics vary by model.
Air Filter Cleaning:
Frequent cleaning or replacement recommended, especially in dusty conditions.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment is critical for drivetrain longevity.
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for exact specification).
Common Wear Items:
Clutch plates, valve seats, cam chain tensioners, water pump seals, exhaust headers (cracking on some models).
Carburetor Tuning:
Can require careful tuning and maintenance for optimal performance, especially with altitude or temperature changes.
Electrical Gremlins:
Older bikes can develop intermittent electrical issues; a good wiring diagram is essential.
Example Oil Filter Part Number:
Refer to manual for specific OEM or aftermarket part numbers for oil filters (e.g., HIFLOFILTRO HF155 or similar).
Ktm Heritage:
KTM, an Austrian manufacturer, has a strong heritage in off-road motorsports, which heavily influenced the LC4 line's design and capabilities.
Lc4 Development:
The LC4 platform evolved significantly through the 1990s and early 2000s, with incremental updates to engines, chassis, and components to meet diverse market demands.
Manufacturing Origin:
Austria
