🏷️ Basic Information

Make:

KTM

Model:

640 LC4

Year:

2003

Vehicle Type:

Motorcycle

Chassis Code:

LC4 640

Generation:

4th Generation LC4

Product Id:

KTM03640LC4OM

👋 Introduction

Market Position:

The 2003 KTM 640 LC4 was positioned as a versatile dual-sport motorcycle, capable of both off-road adventures and street commuting. It appealed to riders seeking a rugged, performance-oriented machine with a potent single-cylinder engine.

Competitive Analysis:

Competed against other large-bore single-cylinder dual-sports and adventure bikes from manufacturers like BMW (F650GS), Honda (XR650L), Suzuki (DR650SE), and Yamaha (XT660R).

Key Features:

Powerful LC4 engine, robust chassis, long-travel suspension, off-road oriented ergonomics, distinctive KTM styling.

📋 Manual Details

Coverage Areas:

Operation, Maintenance, Troubleshooting, Specifications, Safety

Page Count:

53

Manual Type:

Owner's Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine, Fuel System, Ignition System, Clutch, Transmission, Suspension (Front and Rear), Brakes (Front and Rear), Electrical System, Lighting, Controls, Chassis, Wheels, Tires, Lubrication, Cooling System, Exhaust System, Instruments and Displays, Recommended Accessories

Procedures Included:

Pre-ride Inspection, Starting Procedure, Riding Instructions, Parking, Basic Maintenance (Oil Change, Air Filter Cleaning, Chain Adjustment), Tire Pressure Adjustment, Brake Lever Adjustment, Clutch Lever Adjustment, Troubleshooting Common Issues, Safety Precautions, Care and Cleaning

Technical Depth:

Basic to Intermediate owner-level maintenance and operational guidance. Does not cover in-depth engine rebuilds or complex electrical diagnostics typically found in a service manual.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Print Quality:

High Resolution, suitable for digital viewing and printing.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Four-stroke single-cylinder, liquid-cooled

Displacement:

625 cc (actual displacement may vary slightly based on exact sub-model, typically 640cc for LC4 variants)

Bore X Stroke:

101 mm x 78 mm (approximate)

Compression Ratio:

11.0:1 (typical for LC4)

Valve Train:

SOHC, 4 valves per cylinder

Horsepower:

Approximately 50-55 HP (at crank, varies with tuning and variant)

Torque:

Approximately 55-60 Nm (at crank, varies with tuning and variant)

Fuel Delivery:

Carburetor (Mikuni TM40 or similar)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON + MON)/2

Oil Capacity:

1.8 Liters (with filter change)

Oil Type Specification:

SAE 10W-50, API SG or higher, JASO MA certified motorcycle oil recommended.

Cooling Type:

Liquid Cooling

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate clutch

Gear Ratios:

Specific ratios are detailed in the full service manual; however, typical for dual-sports of this era are geared towards a balance of low-end torque and top-end cruising.

Final Drive:

O-ring sealed chain drive

Transmission Oil Type:

Same as engine oil (SAE 10W-50, API SG/JASO MA)

📐 Dimensions

Length:

Approximately 2,200 mm (varies by specific model variant)

Width:

Approximately 850 mm (at handlebars)

Height:

Approximately 1,300 mm (to top of windscreen, if equipped)

Seat Height:

Approximately 940 mm (unladen)

Ground Clearance:

Approximately 300 mm

Dry Weight:

Approximately 155-160 kg (varies by model variant and equipped accessories)

Gross Vehicle Weight Rating:

Typically around 350-370 kg

Fuel Tank Capacity:

13 Liters (including reserve)

Wheelbase:

Approximately 1,500 mm

🛡️ Safety Features

Safety Ratings:

Motorcycles are not subject to the same formal safety rating systems (e.g., NHTSA crash tests) as passenger cars. Safety is inherent in design, rider skill, and adherence to operating procedures.

Active Features:

Disc Brakes (Front and Rear), Spoked Wheels, Off-road Bias Tires, High Ground Clearance, Ergonomic Controls

Passive Features:

Robust Frame Construction, Protective Bodywork (minimal), Operator Awareness required

Safety Recommendations:

Always wear appropriate protective gear (helmet, riding suit, gloves, boots), operate at safe speeds, be aware of road conditions, and perform regular maintenance.

💡 Technology Features

Infotainment Features:

Basic digital/analog instrument cluster displaying speed, RPM, odometer, trip meter, and basic warning lights.

Driver Assistance Features:

None (as per typical dual-sport motorcycle design of the era).

Connectivity Features:

None.

🔧 Maintenance

Oil Change Interval:

Every 5,000 km or 6 months, whichever comes first. Frequent checks are recommended.

Air Filter Cleaning Interval:

Every 3,000 km or more frequently in dusty conditions.

Spark Plug Replacement Interval:

Approximately 10,000-15,000 km (specific type and gap mentioned in manual).

Valve Clearance Check Interval:

Every 10,000 km (crucial for LC4 engine health).

Chain Lubrication And Adjustment:

Lubricate every 500 km, adjust slack as needed (refer to manual for precise slack spec).

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors. (KTM recommends specific proprietary coolant, but any reputable motorcycle coolant meeting spec is acceptable).

Fork Oil Type And Level:

Specific viscosity and fill level are detailed in the manual, typically a light-weight suspension fluid.

Known Issues:

Potential for cam chain tensioner wear (recommend aftermarket upgrade for longevity), occasional carburetor tuning sensitivity, clutch slave cylinder leaks (some early models), spark plug thread wear (ensure proper torque).

Preventative Measures:

Adhering strictly to maintenance schedules, especially valve checks and oil changes, and considering aftermarket upgrades for known wear points can significantly improve reliability.

📚 Vehicle History

Brand Heritage:

KTM, founded in Austria in 1934, has a strong heritage in off-road racing, particularly motocross and enduro. This racing DNA is evident in the performance and robustness of their street-legal models.

Model Evolution:

The LC4 (Liquid Cooled 4-stroke) engine platform has been a cornerstone of KTM's lineup for decades, evolving through various displacements and chassis configurations. The 640 LC4 represented a mature iteration of this successful platform, balancing power and versatility.

Production Years:

The 640 LC4 platform was produced for many years, with the 2003 model year representing a specific iteration. Successors included the 690 LC4 platform.

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions:

While specific awards for the 2003 640 LC4 might not be readily documented, the LC4 platform itself is widely recognized for its performance and off-road capability, often praised in motorcycle publications of its time for its raw power and versatility.

Ratings:

User reviews and magazine tests typically highlight its strong engine performance and off-road prowess, while sometimes noting its firm suspension and vibration characteristics inherent to large single-cylinder engines.