KTM 640 ADVENTURE1999 User manual

Art.Nr. 3.205.70
1.99
Supplement to the OWNER’S HANDBOOK
Art.Nr. 3.205.56
Ergänzungen zur BEDIENUNGSANLEITUNG
Art.Nr. 3.205.56
640 ADVENTURE
mit MIKUNI Vergaser
with MIKUNI carburetor
’99

ENGLISH
1
OPERATION INSTRUMENTS
Page 5:
Ignition lock with 4 switch positions
Switch positions of ignition lock 3:
Ignition off, light off (engine can't be started)
Ignition on, light off (engine can be started)
Ignition on, light on (engine can be started)
Ignition off, light 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The ignition key can be withdrawn in position and .
Page 9:
HOT START DEVICE - not applicable
Page 11:
HELMET LOCK - not applicable
3
CHANGES AND SUPPLEMENTATION OF
OWNERS HANDBOOK 3.205.56 FOR
640 ADVENTURE WITH MIKUNI CARBURETOR

ENGLISH
2
– Do not drive along off-road tracks which go beyond your
ability and experience.
– Hold the handlebar with both hands and leave your feet on
the foot rests while driving.
– Remove your foot from the foot brake pedal when you are
not braking. If the foot brake pedal is not released the brake
pads rub continuously and the braking system is overhea-
ted.
– You may only be accompanied by a passenger if your
motorcycle is fitted and registered for such purposes. The
passenger must hold tight to the brackets or hold on to the
driver during the drive, with his feet on the passenger foot
rests.
– Do not make any alterations to the motorcycle and always
use ORIGINAL KTM SPARE PARTS. Spare parts from other
manufacturers can impair the safety of the motorcycle.
– Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be
secured as close as possible to the middle of the vehicle; dis-
tribute the weight evenly between the front and rear wheel.
Never exceed the maximum permissible laden weight and
the axle weights. The maximum permissible laden weight is
made up of the following components:
– 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
100 kilometers. The vehicle must be run in at low, changing
performance level for the first 1000 KM (620 miles). The maxi-
mum number of revolutions per minute must not go exceed
4800 rpm. Do not accelerate the engine up to the red mark on
the tachometer (8500 r.p.m.) during a running-in period of
1000 km. Exceeding the above listed rotations as well as pus-
hing high rpm when the engine is cold will have an adverse
effect on the life of your engine.
NOTE:
DURING THE STAGE OF RUNNING THE ENGINE IN, THAT IS THE FIRST 1000
KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF A MINERAL OIL
FORMULA. THIS ALSO APPLIES IF THE ENGINE HAS BEEN REPAIRED.
Check the following before each start
When you start off, the motorcycle must be in a perfect technical
condition. For safety reasons, you should make a habit of perfor-
ming an overall check of your motorcycle before each start.
The following checks should be performed:
1 CHECK THE OIL LEVEL
Insufficient oil results in premature wear and consequently
to engine damage.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the
filler cap, check that the tank venting hose is free of kinks.
3 CHAIN
A loose chain can fall off; an extremely worn chain can tear,
and insufficient lubrication can result in unnecessary wear to
the chain and rear sprockets.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must
be replaced. The tread depth must comply with the legal
regulations. Also check the air pressure. Insufficient tread
and incorrect air pressure reduce the driving performance.
5 BRAKES
Check correct functioning of the braking system. Check for
sufficient brake fluid in the reservoir. The reservoirs have
been designed 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 indi-
cates 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 bra-
king system can be expected.
Also check the state of the brake hoses and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake pedal.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING LIQUID
Check the level of cooling liquid when the engine is cold.
8 ELECTRICAL SYSTEM
Check headlight, parking light, tail light, brake light, flas-
hers, indicator lamps and horn for faultless operation.
9 LUGGAGE
If you are taking luggage with you, check that this is secu-
rely fastened.

WARNING

–W
EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER
KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A
JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A
SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY
COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS
EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED
SUITABLE PROTECTIVE CLOTHING.
–D
O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–O
NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR
EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF
THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT
DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING PRO-
PERTIES.
–T
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.
Instructions for initial operation
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– Read the entire manual carefully before your first drive.
– Familiarize yourself with the operating elements.
– Adjust the foot brake pedal to the most comfortable positi-
ons for you.
– Get used to handling the motorcycle on an empty car park,
before starting on a longer drive. Also try to drive as slowly
as possible and in standing position, to improve your feeling
for the vehicle.
DRIVING INSTRUCTIONS

ENGLISH
3
Starting when the engine is cold
1 Open the fuel tap.
2 Turn on the ignition (ignition key position: ).
3 Switch the gear to neutral (green lamp 1lights).
4 Switch on the emergency off switch 2(symbol must be visible).
5 Operate the choke lever 3.
6 Operate the starter tip switch 5without accelerating.
7 If the engine starts, push the choke lever back a little bit, as soon as the
engine runs unevenly.
8 Swing up the centerstand

WARNING

DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS
PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
–M
AXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5
SECONDS BEFORE TRYING AGAIN.
–D
ON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN
COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED
CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN MIND THAT THE ENGINE
SHOULD BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M.
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE
STARTER TIP SWITCH:
– the transmission is switched to idle
– Check if the emergency OFF switch 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“
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 „Trouble-
shooting“ section or contact a KTM dealer.
NOTE:
THIS MOTORCYCLE IS EQUIPPED WITH A SAFETY STARTER SYSTEM. THE ENGINE CAN ONLY
BE STARTED WHEN THE TRANSMISSION IS SWITCHED TO IDLE OR THE CLUTCH LEVER IS
PULLED, RESPECTIVELY.
THE ELECTRIC STARTER DOESN’T CRANK THE ENGINE WHEN THE STAR-
TER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELECTRIC
CURRENT IS AVAILABLE:
– Pull the hand decompression lever 6, start and release the lever.
Starting when the engine is warm or hot
1 Open the fuel tap.
2 Turn on the ignition (ignition key position: ).
3 Switch the gear to neutral (green lamp 1lights).
4 Switch on the emergency off switch 2(symbol must be visible).
5 Operate the starter switch 5without accelerating.
6 Swing up the centerstand
What to do when the engine is „flooded”
The throttle must be fully opened when starting. If necessary change spark
plug.
2
5
3
6
1

ENGLISH
4
Kickstart instructions
Start as described above, then push the kickstarter hard all the way.

WARNING

WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER
TO AVOID INJURIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE
MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly
release the clutch lever and open throttle at the same time.

WARNING

B EFORE YOU START OFF , CHECK THAT THE CENTER STAND HAS BEEN
SWUNG RIGHT UP TO THE TOP
. I F THE STAND DRAGS ON THE GROUND ,
THE MOTORCYCLE CAN GO OUT OF CONTROL
.
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption.
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch lever
and start. It is not necessary to switch the gear to NEUTRAL.

WARNING

–OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING
TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE.
–A
DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–DRIVE CAREFULLY ON UNKNOWN ROADS
–NEVER LEAVE A HELMET ATTACHED TO HELMET LOCK WHEN RIDING
YOUR MOTORCYCLE BECAUSE THE HELMET CAN GET CAUGHT IN THE
REAR WHEEL AND THROW THE VEHICLE OUT OF CONTROL.
–R
EPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY
OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR
GOGGLES, YOU WILL BE PRACTICALLY BLIND.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
!
CAUTION
!
–H
IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN
THIS RESPECT NEED BE TAKEN.
–S
HIFT TO THE NEXT HIGHER GEAR BY 8500 RPM AT THE LATEST.
–
N EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A
LOWER GEAR
. T HE ENGINE WILL OVERSPEED , DAMAGING THE VALVES .
I
N ADDITION , THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL
.
–IF THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE
YOU ARE DRIVING, THIS INDICATES COOLING SYSTEM TROUBLE. IMME-
DIATELY STOP AND TURN OFF THE ENGINE. DRIVING WITH THE WAR-
NING LAMP ON WILL CAUSE ENGINE DAMAGE.
– PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY,
SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE.
CAUTION SCALDING HAZARD! - AND CHECK THE COOLING
LIQUID LEVEL.
– DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COO-
LING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS AS
SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.
–IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT
THE ENGINE FASTENING SCREWS ARE TIGHT.
–I
N THE EVENT THAT, WHILE RIDING YOUR MOTORCYCLE, YOU NOTICE
ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN
THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER.
Braking
Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving downhill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND
BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE
BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN
FAIL.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To stop
the engine, switch off the ignition. Close fuel tap. Park on solid
ground and lock the vehicle.

WARNING

–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
–MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE
DISCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT
TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE,
AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO
TOUCH IT AND GET BURNED.
–N
EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE
HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERI-
ALS.!
CAUTION
!
–P
ARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDE-
STAND (HARD GROUND, LEVEL SURFACE) AND CAN’T TIP OVER.
–T
HE FUEL TAPS MUST ALWAYS BE CLOSED WHEN PARKING THE
MOTORCYCLE. OTHERWISE THE CARBURETOR CAN OVERFLOW AND
FUEL COULD FLOW INTO THE ENGINE.
–A
LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR
MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED
PERSONS.

ENGLISH
5
NOTE REGARDING THE CENTER STAND:
We advice the following procedure to place the motorcycle on the center
stand as effortlessly as possible:
a) press main stand to ground using foot,
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
!
B EFORE YOU START OFF , CHECK THAT THE CENTER STAND HAS BEEN SWUNG RIGHT UP TO THE
TOP
. I F THE STAND DRAGS ON THE GROUND , THE MOTORCYCLE CAN GO OUT OF CONTROL .

ENGLISH
6
Page 26:
FUSE / FAN - not applicable
Fuses for individual power-consuming units
Additional fuses separately protecting different power-consuming units are
mounted under the cockpit cover.
The fuses can be pulled out underneath the cockpit cover for replacement.
Fuse 2(10 Ampere) protects the following power-consuming units:
– headlight
– parking light
– tripmaster
Fuse 3(10 Ampere) protects the following power-consuming units:
– flasher lights
– brake light - foot brake lever
– horn
– radiator fan
Fuse 4(10 Ampere) protects the following power-consuming units:
– ignition
– starter system
– brake light - hand brake lever
Replace a blown fuse only with an equivalent one. If a new fuse that has
just been set in gets blown again, you are strongly advised to have it
inspected by a KTM dealer.
!
CAUTION
!
UNDER 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!
Adjust idling speed *
Use the adjusting screw 5to adjust the basic position of the throttle valve
and, thus, the idle speed.Turning in clockwise direction will increase the
idling speed, turning in counterclockwise direction will reduce the idling
speed. Normal idling speed 1400 - 1500 rpm.
Adjusting the throttle cable *
A play of 3-5 mm must at any time be left in the throttle cables. To check
the play of the throttle cables, first push back the protective cap 7on the
throttle twist grip. Now it should be possible to lift the outer sleeve of one
of the two cables 3-5 mm off the adjusting screw 8before resistance is
felt. The play of the throttle cables can be adjusted, if necessary, using the
two adjusting screws.
For this purpose, undo counter nut 9and turn the adjusting screw until the
desired play is achieved. Then tighten the counter nut and replace the
protective cap.
MAINTENANCE WORK ON CHASSIS AND ENGINE
3-5 mm
7
8
9
2
3
4
5

ENGLISH
7
TROUBLE SHOOTING
If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
TROUBLE
Engine doesn’t crank.
The engine doesn't crank.
The neutral indicator lamp
doesn't light up.
The engine cranks only with
pulled clutch lever
Engine cranks with gear
engaged.
Engine cranks but doesn’t
start.
CAUSE
Operating errror
Discharged battery.
Defect ignition lock or emergency
OFF switch
Blown fuse safe-starting system.
Blown main fuse.
Discharged battery.
Defect safe-starting system.
Defect safe-starting system.
Operating error
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has accu-
mulated in the float chamber
Fuel supply interrupted
Defective fuel pump
Flooded engine
Sooty or wet spark plug
Electrode gap too large
REMEDY
Turn on the ignition, switch the gear to neutral and switch the
emergency OFF switch on.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Check ignition lock and emergency OFF switch, contact a
KTM dealer.
Replace fuse (below the cockpit cover).
Remove seat and replace the main fuse. If fuse blows again
contact a KTM dealer.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Contact a KTM dealer.
Contact a KTM dealer.
Open fuel tap / emergency fuel tap, tank fuel, you did not use
choke i.e. the warmstart device. Pay attention to starting off
information (see driving instructions).
The easily inflammable components of the new fuels evapo-
rate during longer periods of standstill.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old fuel
from the float chamber. The engine will immediately start off
when the float chamber is filled with new fuel.
Disconnect the fuel hose coming from the fuel tap at the fuel
pump. Put the end of the fuel hose into an appropriate contai-
ner and open the fuel tap.
– If fuel flows out, check the fuel pump.
–
If no fuel flows out, the fuel evaporation control system must
be checked or the fuel tap must be cleaned, respectively.
Disconnect the fuel hose at the carburetor. Put the end of the
fuel hose into an appropriate container, open the fuel taps
and start the engine.
– If fuel flows out, clean the carburetor.
– If no fuel flows out
– check the underpressure tube between the cylinder head
and the fuel pump for leaks.
– check if the fuel filter is clogged.
– contact a KTM dealer.
Fully open the throttle when starting or exchange the spark
plug, respectively
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug elektrode gap to 0,7 mm

ENGLISH
8
TROUBLE
Engine cranks but doesn’t
start.
Engine fails to idle
Engine does not rev high
Engine will not reach full
power
CAUSE
Spark plug connector or spark plug
faulty
The plug connection of the CDI-
unit, the pulse generator or the
ignition coil has oxydized
Water in carburetor or jets blocked
Carburetor does not fit in properly
at intake flange
Glogged idling jet
Oncorrect adjustment of adjusting
screws on carburetor
Defective spark plug
Defective ignition system
Carburetor fuel level too high
because
Float needle is dirty or worn out
Float leaks
The cold starting system is perma-
nently activated due to a lack of
play in the choke cable.
Defective membrane of slide
Carburetor leaking
Loose carburettor jets
Electronic ignition timing faulty
Fuel supply partically interrupted or
carburetor dirty
Float leaks
Defective membrane of slide
Carburetor leaking
Air filter very dirty
Valve clearance to small
Loss of compression because hand
decompressor has no play
Electronic ignition timing faulty
REMEDY
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate starter, a strong spark
must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn't produce a spark either, dis-
connect the spark plug connector from the ignition cable,
hold it a distance of approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Remove the seat, the right side cover and the fuel tank. Clean
the plug connection and treat it with contact spray
Dismount and clean carburetor
Check if carburetor is fitted in correctly
Disassemble 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.
Replace membrane
Check vacuum hose and venting hose of carburetor for cor-
rect position (no kinks)
Tighten jets
Have ignition system checked
Clean and check fuel system as well as carburetor
Have fuel pump checked.
Replace the float
Replace membrane
Check vacuum hose and venting hose of carburetor for cor-
rect position (no kinks)
Clean or replace air filter, contact a KTM dealer
Have valve clearance adjusted
Check setting of the hand decompression cable
Have ignition system checked

ENGLISH
9
TROUBLE
Engine overheats
High oil consumption
Electric system not
operational
All switched on lamps blown
out
Headlight and parking light
fail, no power on tripmaster
Flasher lights, brake light,
fan and horn fail
The NEUTRAL lamp is not
on even though the gear is
in NEUTRAL
The battery is discharged
No values are visible in the
Tripmaster display.
No speed display.
A time entry is requested by
the Tripmaster every time
the ignition is switched on.
CAUSE
Insufficient cooling liquid
Radiator fins are extremely dirty
Foam forms in cooling system
Bent radiator hose
Thermostat defective
Blown fan fuse
Defect thermoswitch
Fan defective
Buckling gear ventilation hose
Engine oil level too high
Engine oil too thin (viscosity)
Blown main fuse.
Discharged battery.
Voltage regulator faulty
Blown fuse
Blown fuse
Defect indicator lamp.
Defect neutral switch.
Loose connections, defect cable.
The ignition (power consumer)
hasn’t been switched off
The battery isn’t charged by the
generator because
The contrast potentiometer is set
incorrectly.
Defective sensor cable or oxidized
socket connector.
The lithium battery in the device is
empty.
REMEDY
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Clean radiator with water jet
Replace cooling liquid, use antifreezer with brand name
Shorten or replace cooling hose
Remove and check thermostat (opening temperature 70°C
(158°F) or replace it, contact a KTM dealer
Replace fuse and check if fan operates properly (see below)
Contact a KTM dealer
Check if fan operates properly. To do this, start the engine,
then bypass the connections to the thermoswitch (bottom
right radiator), contact a KTM dealer
Readjust or replace ventilation hose
Check engine oil level when the engine is warm; correct if
necessary
Use thicker engine oil; see chapter „Engine oil“
Remove seat and replace the main fuse. If fuse blows again
contact a KTM dealer.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Remove seat and check connections. Have voltage regulator
checked
Replace fuse (below the cockpit cover).
Replace fuse (below the cockpit cover).
Replace indicator lamp
Connect cable to ground; neutral switch must be replaced if
indicator lamp lights up.
Check connections and cables.
Recharge the battery according to the relevant instructions.
Remove seat and check voltage regulator connections; voltage
regulator and generator should be checked by a KTM dealer.
Turn the contrast potentiometer until the display can be easily
read.
Check the sensor cable for damage and replace it if necessary.
Remove the headlight mask and check the socket connector.
Contact a KTM dealer.
Contact a KTM dealer.

ENGLISH
10
TECHNICAL DATA – ENGINE 640 ADVENTURE R ‘99 Mikuni carburetor
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
slide stop 17 mm
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
–
640 Adventure
25 kW
640 Adventure
37 kW

KTM-SPORTMOTORCYCLE AG
A-5230 Mattighofen • Postfach 91 • Austria
Internet: http://www.ktm.co.at
FN 102019 d - Landesgericht Ried im Innkreis