🏷️ Basic Information

Make:

KTM

Model:

640 LC4

Sub Model:

640 Supermoto

Year:

2002

Chassis Code:

LC4 (specific generation variant for 2002)

👋 Introduction

Market Position:

Essential resource for owners and technicians of the KTM 640 LC4 and 640 Supermoto models from 2002, particularly for maintaining and repairing the chassis and associated non-engine parts.

Competitive Analysis:

This parts manual distinguishes itself by focusing solely on chassis components, providing a granular view of these systems without the complexity of an integrated engine/chassis service manual. This specificity is valuable for parts sourcing and visual assembly guidance.

Key Features:

Fully illustrated with detailed exploded views of all chassis-related parts, enabling accurate identification and procurement of replacement components. Aids in the systematic disassembly and reassembly of the motorcycle's structural and rolling chassis elements.

📋 Manual Details

Coverage:

Chassis parts only (excluding engine components)

Page Count:

Estimated (Manual description does not specify, typical for illustrated parts lists of this era range from 100-300 pages)

Manual Type:

Illustrated Parts List / Parts Catalog

Language:

English (Standard for KTM manuals of this period unless otherwise specified)

Format:

Printed (implied by sales context, could also be digital PDF)

📖 Manual Coverage

Chassis Components:

Frame, swingarm, suspension (forks, rear shock absorber), wheels, brakes (calipers, discs, master cylinders), steering assembly, fuel tank, seat, bodywork (fenders, side panels, chain guard), exhaust system (muffler, headers - as chassis-mounted parts), footpegs, handlebars, levers, controls, lighting, electrical wiring harness routing (as it pertains to chassis mounting), fasteners, and related hardware.

Assembly Disassembly Assistance:

Provides exploded views and part identification to aid in disassembly and reassembly of chassis components.

Technical Depth:

Detailed part identification and visual breakdown for sourcing replacement parts and understanding component relationships. Does not provide repair procedures or torque specifications.

📊 Manual Specifications

File Format:

Print (Assumed from product description for sale. If digital, it would typically be PDF)

Print Quality:

High-quality, durable paper suitable for workshop environments. Illustrations and exploded views are clear and legible.

Binding Type:

Staple-bound or perfect bound (typical for motorcycle manuals)

Paper Type:

Matte finish, heavy-weight paper to withstand workshop use.

⚙️ Engine Specifications

Engine Type:

LC4 Single Cylinder (4-stroke) - *Note: Engine details are NOT covered in this manual, but are essential context for the vehicle.*

Horsepower:

Approx. 54-60 HP (for 640 LC4 variants in 2002) - *Note: Engine details are NOT covered in this manual.*

Fuel System Type:

Carburetor (Keihin CVK 41 or similar) or Fuel Injection (depending on specific sub-model variant) - *Note: Engine details are NOT covered in this manual.*

🔧 Transmission

Transmission Type:

5-speed constant mesh - *Note: Transmission details are NOT covered in this manual, but are chassis-adjacent.*

Clutch Type:

Wet multi-disc clutch - *Note: Transmission details are NOT covered in this manual, but are chassis-adjacent.*

📐 Dimensions

Wheelbase:

Approx. 1465 mm (57.7 in) for 640 LC4 - *Note: Specific dimensions for Supermoto may vary slightly and are not detailed in the product description.*

Seat Height:

Approx. 860 mm (33.9 in) for 640 LC4 - *Note: Specific dimensions for Supermoto may vary slightly and are not detailed in the product description.*

Dry Weight:

Approx. 148 kg (326 lbs) for 640 LC4 - *Note: Specific dimensions for Supermoto may vary slightly and are not detailed in the product description.*

Fuel Capacity:

Approx. 17 liters (4.5 US gal) for 640 LC4 - *Note: Specific dimensions for Supermoto may vary slightly and are not detailed in the product description.*

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety ratings are not standardized in the same way as automobiles. Focus is on rider safety through design and component integrity.)

Braking System:

Disc brakes (front and rear) with hydraulic actuation. Specific caliper and disc sizes are detailed within the manual for parts identification.

Frame Construction:

Chromium-molybdenum steel trellis frame (typical for KTM LC4 models of this era), designed for rigidity and rider feedback. Detailed in the manual for parts sourcing.

💡 Technology Features

Infotainment Features:

N/A (Motorcycle of this era is focused on core mechanical function, not infotainment. The manual covers basic electrical system components related to lighting and ignition as part of the chassis.)

Driver Assistance Features:

N/A (Motorcycles of this era do not feature electronic driver assistance systems like ABS or traction control as standard or common options. The manual focuses on mechanical systems.)

🔧 Maintenance

Suspension Service Interval:

While this manual does not list service intervals, it is crucial for locating parts for suspension fork seals, shock linkage bearings, and brake pad replacements, which typically require attention based on riding conditions and mileage (e.g., fork seals every 10,000-20,000 km).

Brake Fluid Type:

DOT 4 (standard for hydraulic brake systems) - *Note: Specific fluid types are generally found in owner/service manuals, not parts lists, but this manual helps identify the components needing fluid.*

Known Chassis Issues 2002 Lc4:

Common areas for wear or replacement on LC4 chassis can include wheel bearings, steering head bearings, swingarm pivot bearings, and suspension seals due to the performance-oriented nature of the bikes. This manual is vital for identifying the correct replacement parts for these components.

Part Number Identification:

The manual's primary function is to provide exact KTM part numbers for all illustrated chassis components, essential for accurate ordering and ensuring compatibility.

Chain Lubrication Schedule:

While not provided, maintaining the drivetrain (chain, sprockets) is critical for chassis longevity and performance. This manual can identify chain guard and sprocket components for replacement.

📚 Vehicle History

Brand Heritage:

KTM AG, an Austrian manufacturer, has a rich history in off-road and racing motorcycles, known for its 'Ready to Race' philosophy. The LC4 platform has been a cornerstone of their street-legal single-cylinder lineup for decades.

Model Evolution Lc4:

The LC4 (Liquid Cooling 4-stroke) engine was introduced in the late 1980s and has seen continuous development. The 640cc variant represents a significant iteration, offering a blend of power and versatility, with 'Supermoto' versions featuring enhanced suspension and braking for street performance.

Production Period 640:

The 640 LC4 models were produced roughly from the mid-1990s through the mid-2000s, with the 2002 model being a key year within this production run.

🏆 Awards & Recognition

Awards Lc4:

While specific awards for the 2002 640 LC4 Supermoto are not readily documented, the LC4 platform has consistently received praise in motorcycle reviews for its performance, handling, and off-road capability, translating to strong enthusiast following and aftermarket support.