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KTM · Overhead-cam four-stroke single, dry sump, gearbox shares engine oil, chain drive

Supermoto 640

Library entry covers 1999-2007

47 factory 50 guideline

Published source

KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006 (art. no. 3.211.78 EN), periodic maintenance schedule pp.18-19 (manualsdir 156075)

Factory source. Covers 2006 model (cover prints 640 LC4 ENDURO / 640 LC4 SUPERMOTO, owner's manual 2006); catalog rows span 1999-2007, other years may differ.

97 items for a 2000 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)
Engine cycle
Four-stroke
Engine lubrication
Dry sump (separate oil tank)
Oil filtration
Replaceable cartridge or spin-on filter
Valve gear
Overhead cam, screw/locknut adjusters
Ignition
Electronic (CDI / transistor / ECU)
Charging
Alternator / stator with rectifier
Battery
Wet cell (flooded lead-acid, needs topping up)
Fuel system
Single carburetor
Cooling
Liquid cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Shares engine oil
Clutch control
Hand lever, cable
Final drive
Chain
Front suspension
Telescopic fork
Rear suspension
Swingarm, single shock / cantilever
Front brake
Disc, hydraulic
Rear brake
Disc, hydraulic
Wheels
Cast / alloy, tubeless
Sidecar
No sidecar
Maintenance schedule

2000 KTM Supermoto 640

On the road: every 300 km

1 item
  • Check engine oil level
    Pre-ride / on the road
    Guideline

    Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline
  • Lubricate drive chain
    Pre-ride / on the road
    Guideline

    Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item
  • Check coolant level
    Pre-ride / on the road
    Guideline

On the road: every 1,000 km

1 item
  • Check chain slack and rear wheel alignment
    Pre-ride / on the road
    Guideline

Every 1,600 km or 6 months

1 item
  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Guideline

Every 5,000 km or 12 months

10 items
  • Check throttle cable(s) free play and return
    Fuel and air
    Guideline
  • Clean fuel tap filter / sediment bowl
    Fuel and air
    Guideline
  • Clean drive chain thoroughly (remove and soak, re-lube)
    Final drive
    Guideline

    Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    Guideline
  • Check steering head bearing adjustment
    Front end
    Guideline
  • Inspect fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Grease and check center / side stand and springs
    Rear suspension and frame
    Guideline
  • Check brake pads and discs
    Brakes
    Guideline
  • Check wheel bearings for play
    Wheels and tires
    Guideline

Every 5,000 km

38 items
  • All chassis screws (check tight)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • All screws and nuts (check tight)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Breather hoses (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Cooling system leaks and antifreeze (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Electrical system function (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Engine fastening screws (check tight)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Engine oil, oil filter and fine filter (change)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Exhaust system leaks and mounting (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • External engine screws (check tight)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Headlamp adjustment (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Idle setting (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Oil lines (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Oil screens and drain plug magnet (clean)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Radiator fan (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Spark plug (check, adjust)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Sprocket screws and locking (check)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Valve clearance (check, adjust)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Air filter and filter box (clean)
    Fuel and air
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Carburetor connection boots (check)
    Fuel and air
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Hydraulic clutch master cylinder oil level (check)
    Primary and gearbox
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Chain (lubricate)
    Final drive
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Chain and chain guides (check wear, fit, tension)
    Final drive
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Fork dust sleeves (clean)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Fork legs (bleed)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Shock absorber and fork (check for leaks and function)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Steering head bearing (check, adjust)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Shock absorber O-ring (check wear)
    Rear suspension and frame
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Swingarm pivot (check)
    Rear suspension and frame
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Brake fluid level, lining thickness and discs (check)
    Brakes
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Brake lines (check)
    Brakes
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Brake system screws (check tight)
    Brakes
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Hand and foot brake levers free travel (check, adjust)
    Brakes
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Spoke tension and rim joint (check)
    Wheels and tires
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Tire condition and pressure (check)
    Wheels and tires
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Wheel bearings and cush drive (check)
    Wheels and tires
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Actuating cables (check, adjust, lubricate)
    Controls and cables
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). After 1,000 km, then every 5,000 km.

  • Cables routing (check)
    Controls and cables
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

  • Linkage lever (lubricate)
    Controls and cables
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 5,000 km.

Every 6,500 km or 12 months

2 items
  • Inspect, clean and gap spark plugs
    Engine
    Guideline
  • Adjust clutch free play, lubricate cable and lever pivot
    Primary and gearbox
    Guideline

Every 8,000 km or 12 months

2 items
  • Change engine oil
    Engine
    Guideline

    Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.

  • Replace oil filter
    Engine
    Guideline

Every 9,500 km or 12 months

8 items
  • Inspect coolant hoses and clamps
    Engine
    Guideline
  • Clean / inspect air filter
    Fuel and air
    Guideline

    Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.

  • Clean carburetor float bowl(s), check float level and jets
    Fuel and air
    Guideline

    Ethanol fuel varnishes old carbs quickly in storage.

  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check swingarm bushes for play
    Rear suspension and frame
    Guideline
  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Guideline
  • Lubricate control cables and lever pivots
    Controls and cables
    Guideline
  • Lubricate speedometer / tachometer cables, check drive
    Controls and cables
    Guideline

    A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km

1 item
  • Spark plug (replace)
    Engine
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Every 10,000 km.

Every 13,000 km or 2 years

1 item
  • Check and adjust valve clearances
    Engine
    Guideline

Every 16,000 km or 2 years

1 item
  • Compression test (or leak-down)
    Engine
    Guideline

Every 19,500 km or 2 years

3 items
  • Replace air filter element
    Fuel and air
    Guideline
  • Clean and grease rear suspension linkage
    Rear suspension and frame
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 20,000 km or 2 years

2 items
  • Shock absorber (complete maintenance)
    Rear suspension and frame
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: every 2 years or 20,000 km.

  • Linkage lever (complete maintenance)
    Controls and cables
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: every 2 years or 20,000 km.

Every 24,000 km or 3 years

1 item
  • Change fork oil
    Front end
    Guideline

    Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 25,500 km or 4 years

1 item
  • Replace spark plugs
    Engine
    Guideline

Every 29,000 km

1 item
  • Replace chain and sprockets (wear based)
    Final drive
    Guideline

Every 32,000 km or 4 years

2 items
  • Repack / replace steering head bearings
    Front end
    Guideline

    Many old machines use loose balls in cups and cones. Taper roller conversions are common.

  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

    Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 48,500 km or 6 years

1 item
  • Rebuild forks: seals, bushes, springs
    Front end
    Guideline

Every 6 months

1 item
  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Guideline

Every 12 months

6 items
  • Carburetor (clean and adjust)
    Fuel and air
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

  • Battery connections (contact grease)
    Ignition and electrics
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

  • Electrical contacts and switches (contact spray)
    Ignition and electrics
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

  • Fork (complete maintenance)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

  • Steering head bearing and seals (clean and lubricate)
    Front end
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

  • Brake fluid (change)
    Brakes
    Factory

    Factory: Periodic maintenance schedule (KTM 640 LC4 ENDURO / 640 LC4 SUPERMOTO owner's manual 2006, art. no. 3.211.78 EN, printed pp.18-19; columns 1st service after 1,000 km, 2nd service after/every 5,000 km; supplementary order: at least once a year, every 2 years or 20,000 km; intervals never to be exceeded by more than 500 km; for competition the 5,000 km service after every race). Supplementary order: at least once a year.

Every 2 years

4 items
  • Replace coolant
    Engine
    Guideline
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline
  • Replace brake fluid
    Brakes
    Guideline

Every 4 years

3 items
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

  • Inspect brake hoses; replace old rubber
    Brakes
    Guideline
  • Rebuild calipers and master cylinders (seals)
    Brakes
    Guideline

Every 6 years

1 item
  • Replace tires on age (regardless of tread)
    Wheels and tires
    Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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Other 2000 KTM models

All 2000 KTM
1987-2001
Enduro 125
Guideline
1992-2017, Carb premix
EXC 250
Factory
1995-2025
EXC 300
Factory
1995-2025
SX 50
Factory
1997-2000
LC4 400
Guideline
1997-2001
LC4 600
Guideline
1998-2000
SX 380
Guideline
1999-2007
Adventure 640
Guideline