KTM 640 LC4 User Manual

5 (1)
KTM 640 LC4 User Manual

BEDIENUNGSANLEITUNG2004

640 LC4 ENDURO

640 LC4 SUPERMOTO

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART.NR: 3.210.85

IMPORTANT

WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:

WARNING

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.

!

CAUTION

!

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

Stamp of dealer

COMSUMER INFORMATION FOR AUSTRALIA ONLY

Tampering with noise control system prohibited

Owners are warned that the law may prohibit:

(a)The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

(b)the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS,

MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI-

TUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION.

ENGLISH 1

 

Introduction

 

We would like to congratulate you on your purchase of a KTM motorcycle.

 

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring

 

you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

 

Before you go for your first ride, be sure to read this manual carefully and thoroughly in

 

order to familiarize yourself with how to operate your new motorcycle and with its

 

characteristics, even if this means that you will have to dedicate some of your valuable

 

time to this task. Only by doing so will you learn how to tune your motorcycle to your

ENGLISH

specific needs and how to protect yourself against injury. Besides, this manual contains

work on the chassis and engine" must be performed. If maintenance work should

 

important information on motorcycle maintenance. At the time this manual was typeset,

 

it was up-to-date with the latest state of this production series. It cannot be completely

 

ruled out, however, that minor discrepancies may exist resulting from further design

 

upgrades of these motorcycles.This manual is an important part of your motorcycle and

 

should be passed on to any subsequent owner in case you decide to sell it.

 

We expressly point out that work marked with an asterisk in the chapter "Maintenance

 

become necessary during a competition it should be performed by a trained mechanic.

2KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others.

We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

© by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION

The 640 LC4 Enduro model was designed to resist the usual wear and tear of normal use on the road and easy terrain (unpaved roads).

The 640 LC4 Supermoto model is designed for regular on-road service but not for use off of paved roads.

The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear.

The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty.

The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule.

The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached.

No warranty will be assumed if the bike is used in races or competitions.

ENGLISH 3

In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

ENGLISH 4

INDEX

 

Page

SERIAL NUMBER LOCATIONS .............................................

5

Chassis number ................................................................

5

Engine number, engine type.............................................

5

OPERATION INSTRUMENTS ...............................................

5

Clutch lever ......................................................................

5

Hand decompression lever................................................

5

Hand brake lever ..............................................................

5

Multi-functional digital speedometer ................................

6

Seeting options in the display ...........................................

7

Indicator lamps.................................................................

8

Choke lever ......................................................................

8

Ignition lock .....................................................................

8

Combination switch..........................................................

9

Starter tip switch, emergency OFF switch, light switch .....

9

Filler cap...........................................................................

9

Fuel tap ..........................................................................

10

Shift lever .......................................................................

10

Kickstarter ......................................................................

10

Foot brake pedal ............................................................

10

Compression damping of fork ........................................

11

Rebound damping of fork ..............................................

11

Compression damping of shock absorber .......................

11

Rebound damping of shock absorber .............................

11

Holding bars...................................................................

11

GENERAL TIPS AND WARNINGS FOR STARTING THE

 

MOTORCYCLE...................................................................

12

Instructions for initial operation ......................................

12

Running in the LC4 models ............................................

12

Accessories and payload .................................................

12

DRIVING INSTRUCTIONS ..................................................

13

Check the following before each start ............................

13

Starting when the engine is cold.....................................

14

Starting when the engine is warm or hot ........................

14

What to do when the engine is „flooded“......................

14

Kickstart instructions.......................................................

15

Starting off .....................................................................

15

Shifting, Riding...............................................................

15

Braking...........................................................................

15

Stopping and parkling ....................................................

16

Fuel ................................................................................

16

PERIODIC MAINTENANCE-SCHEDULE ..............................

18

MAINTENANCE WORK ON CHASSIS AND ENGINE ..........

20

Tool set ..........................................................................

20

Removing the seat..........................................................

20

Checking and adjusting steering head bearing................

21

Breather plug front fork..................................................

21

Cleaning the dust sleeves of the telescopic fork ..............

21

Changing the spring preload of the shock absorber ........

22

Lubricate shock absorber linkage ....................................

22

Checking rubber ring on the rear shock absorber............

22

Checking chain tension...................................................

23

Correct chain tension......................................................

23

Chain maintenance.........................................................

24

Chain wear.....................................................................

24

 

Page

General information on KTM disc brakes ........................

 

25

Adjisting of free travel at the hand brake lever ...............

 

26

Changing the basic position of the handbrake lever........

26

Checking of brake fluid level - front brake......................

 

26

Refilling the front brake fluid reservoir............................

 

26

Checking the front brake pads........................................

 

27

Changing the basic position of the foot brake pedal .......

27

Check the rear brake fluid level ......................................

 

28

Refilling the rear brake fluid reservoir .............................

 

28

Checking the rear brake pads .........................................

 

28

Dismounting and mounting the front wheel (LC4) .........

29

Dismounting and mounting the front wheel

 

 

(LC4 Supermoto)............................................................

 

29

Dismounting and mounting the rear wheel.....................

 

30

Checking the shock absorbtion rubbers in the rear hub ..

30

Tires, air pressure............................................................

 

31

Checking spoke tension..................................................

 

31

Changing the wheel size.................................................

 

31

Battery ...........................................................................

 

32

Charging the battery ......................................................

 

32

Fuses ..............................................................................

 

33

Exchanging the headlight lamp.......................................

 

33

Replacing the parking light bulb .....................................

 

33

Exchanging the brake light and tail light bulb .................

 

34

Cooling system...............................................................

 

34

Checking the cooling liquid level ....................................

 

35

Cleaning the air filter ......................................................

 

35

Changing the orginal position of the clutch lever............

36

Checking the oil level of the hydraulic clutch ..................

 

36

Adjusting the throttle cable ............................................

 

36

Checking and adjusting the chocke cable play ................

 

37

Checking the adjustment of the hand decompression cable ..

37

Activating the ignition curve for low-octane fuel

............

37

Adjust idling speed .........................................................

 

37

Draining the carburetor float chamber............................

 

38

Engine oil .......................................................................

 

38

Checking the engine oil level ..........................................

 

38

Oil circuit........................................................................

 

39

Oil and fine screen filter change, bleeding of the oil system ..

39

Changing oil filter ..........................................................

 

40

TROUBLE SHOOTING........................................................

 

41

CLEANING..........................................................................

 

44

CONSERVATION FOR WINTER OPERATION ....................

 

44

STORAGE ...........................................................................

 

44

Re-initation after time of storage....................................

 

44

TECHNICAL SPECIFICATIONS - CHASSIS...........................

 

45

TECHNICAL SPECIFICATIONS - ENGINE ...........................

 

47

HEAD WORD INDEX..........................................................

 

48

WIRING DIAGRAM................................................

APPENDIX

1

A

2

3

B

SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1.

Engine number, engine type

 

ENGLISH

The engine number and engine type are stamped on the right hand side of

 

the engine below the chain sprocket. Write this number into the relevant

 

area on page 1.

 

 

 

5

 

 

OPERATION INSTRUMENTS

 

 

 

 

 

Clutch lever

 

The clutch lever 1 is located on the left side of the handlebar. The adjusting

 

screw A is used to change the original position of the clutch lever (see

 

maintenance work on chassis and engine).

 

Hand decompression lever

 

The hand decompression lever 2 is only used in two special cases:

 

a)When the engine stalled.

 

It is possible that the starter motor is not able to crank the engine on the

 

next attempt. This is due to the fact that the automatic decompressor

 

doesn’t work properly. If this happens, pull the manual decompression

 

lever and start again. Afterwards normal starting will be possible.

 

b) When you want to push the motorcycle.

 

While pushing, pull the hand decompression lever to make it easier to get

 

the engine going.

 

Hand brake lever

 

The hand brake lever 3 is mounted on the handlebars on the right and

 

actuates the front wheel brake. The adjusting screw B can be used to

 

change the basic position of the hand brake lever (see "Maintenance").

 

1

2

3

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TEST

 

6

WS

 

 

CLOCK

 

ODO

 

TRIP 1

 

TRIP 2

 

TRIP F

Multi-functional digital speedometer

The universal instrument is divided into 3 parts.

Use the MODE and SET 1 button to change the display and the basic settings in the display.

Display 2 shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button.

The indicator lamps 3 provide additional information on the motorcycle's running condition.

Display

TEST

When you switch on the ignition, all of the display elements will light up for 1 second for the function test.

WS (wheel size)

The display will change and show the diameter of the front wheel in inches for 1 second (WS = wheel size).

Then the CLOCK mode will be displayed, or the mode that was active when the ignition was switched off.

CLOCK

You will recognize the OK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock.

To switch to the next display mode, press the MODE button.

ODO

The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode.

To switch to the next display mode, press the MODE button.

TRIP 1

The TRIP 1 mode shows the speed, the temperature of the cooling liquid and the trip odometer 1.

To switch to the next display mode, press the MODE button.

TRIP 2

The TRIP 2 mode shows the speed, the temperature of the cooling liquid and the trip odometer 2.

To switch to the next display mode, press the MODE button.

TRIP F

The TRIP F (fuel) mode shows the speed, the temperature of the cooling liquid and the distance traveled since reaching the low-fuel mark (the lowfuel indicator lamp will blink).

To return to the UHR mode, press the MODE button.

1

1

Setting options in the display

KILOMETERS OR MILES.

You can have the speed and distance shown in kilometers or miles in the display. The display can be adapted to the respective country on longdistance trips.

To switch from kilometers to miles, switch on the ignition and press the MODE 1 button for approx. 10 seconds. The km/h display will switch to mph. The speed and the stored distances will be converted and displayed in miles.

To return to kilometers, proceed as described above.

CLOCK

Switch on the ignition and change to the CLOCK mode.

Simultaneously press MODE 1 and SET 2. The numbers on the clock will start to blink. Use the MODE button to set the hours and the SET button to set the minutes.

The press the MODE and SET buttons simultaneously.

NOTE: 0:00 will be displayed if the clock is not supplied with electricity. This can be caused by a defective fuse or a fault in the board electric system (see Troubleshooting).

TRIP 1

The trip meter 1 runs continuously and counts up to 999.9. It can be used to measure the length of a certain route on a trip or the distance between two refueling stops.

To return the trip meter 1 to zero, switch on the ignition, change to the TRIP 1 mode and press the SET button.

ENGLISH 7

2

RESETTING TRIP 2

The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook.

To return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button.

NOTE: A Tripmaster switch (Part no. 582.14.069.044) is available as an accessory and enhances the trip meter 2 functions. You can correct the displayed route by increasing or decreasing in increments of 0.1. For example, if you have taken the wrong road when driving according to a roadbook, you can easily correct the display to correspond to the roadbook again. It can also be used to change the display modes. The switch is mounted on the handlebars so that you can keep your hands on the handlebars.

TRIP F

When the fuel level reaches the reserve mark, the display will automatically switch to TRIP F and begin to count (no matter which display mode was active before). At the same time, the fuel warning lamp will start to blink. You will still have enough reserve fuel for at least 35 kilometers.

After refueling, it will take approx. 3 minutes for TRIP F to automatically reset to 0 and return to the previous display mode.

NOTE: To use up the reserve fuel in the tank, move the fuel cock to the RES position by hand.

120°C (248°F) 110°C (230°F)

1

60°C (140°F)

50°C (122°F)

40°C (104°F)

Cooling liquid temperature display

The temperature display 1 is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning lamp 2 will light up.

 

 

 

 

WARNING

 

 

 

 

 

POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED WARNING LIGHT FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP:

DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEMPERATURES

NOT ENOUGH COOLING LIQUID IN THE SYSTEM

THE VENTILATOR ON THE RADIATOR IS NOT RUNNING

IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY

ENGLISH

 

Indicator lamps

 

The green indicator lamp will blink in the blinker rhythm when the

 

 

 

 

blinker is switched on.

 

2

NOTE:

 

 

The indicator lamp will blink slower when a blinker is broken.

 

 

The green indicator lamp will light up when the gearbox is in an

 

 

idling position.

 

 

The blue indicator lamp will light up when the high beams are

 

 

switched on.

8

 

The red warning lamp will start to blink when the cooling liquid

 

 

reaches 120°C (248°F).

 

 

This warning light has no function.

 

 

This warning light has no function.

 

 

This indicator lamp has no function.

Choke lever

If the choke lever 3 is pulled backwards, a bore will be opened in the carburetor through which the engine may draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. If the choke lever is pushed forward up to the stop, the bore will be closed again. In this position the choke cable must have a play of approx. 4 mm.

 

 

 

Ignition lock with 3 switch positions

 

4

 

Switch positions of ignition lock 4:

 

 

= Ignition off, (engine can't be started)

 

 

 

 

 

 

= Ignition on, (engine can be started)

= Ignition 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 .

4

5

6

7

Combination switch

The rocker switch LIGHTS 1 actuates the high beam or low beam.

= High-beam light = Low-beam light

The light signal (high beam) is actuated with button 2.

The indicator switch 3 returns to central position after actuation.

ENGLISH

Press flasher switch towards switch housing to switch off the flasher.

 

The horn is sounded with button 4.

 

 

 

 

9

Starter tip switch, emergency OFF tip switch, light switch

 

The emergency off switch 5 is provided for emergency situations and

 

should not be used to switch off the engine.

 

 

The engine is ready for operation in position

(ignition circuit and starter

 

circuit are switched on).

 

 

The engine cannot be started in position

(ignition circuit and starter

 

circuit are interrupted).

The light switch has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch 6 to operate the electric starter.

Filler cap

The filler cap 7 can be locked and is provided with a fuel evaporation control system.

To open the cap insert the ignition key, turn it 90° counterclockwise, then lift off the filler cap.

To close the tank insert the filler cap, turn the ignition key 90° clockwise and take out the key.

ENGLISH

OFF

ON

RES

 

RES

 

RES

 

RES

 

F

 

F

 

F

F

U

F

U

F

U

E

E

E

F

F

F

O

L

O

L

O

L

 

ON

 

ON

 

ON

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

 

2,3,4,5

 

 

 

 

 

N

 

 

 

 

 

 

1

 

 

 

Fuel tap

OFF In this position the fuel tap is closed. No fuel may flow to the carburetor.

ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx. 2.5 liters.

RES The reserve, approximately 2.5 liters, cannot be tapped until the twist grip is turned to the RES position. Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time, too.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.

Foot brake pedal

The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

Compression damping of fork

The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap A. By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

BASIC SETTING:

turn rotary knob clockwise as far as it will go

turn it back counter-clockwise by as many clicks as are specified for the

A

 

 

relevant type of fork

 

 

 

 

 

 

 

 

 

 

.............WP 0518Y737

20 Klicks

(640

LC4)

 

 

 

 

 

 

WP 1418Y750 .............

20 Klicks

(640

LC4 Supermoto)

Rebound damping of fork

The rebound damping is to be set at the upper end of the fork tubes. It only regulates the degree of damping during rebounding.

By using the knob 2 (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

2

BASIC SETTING:

 

 

 

 

– turn rotary knob clockwise as far as it will go

 

– turn it back counter-clockwise by as many clicks as are specified for the

 

relevant type of fork

 

 

 

 

WP 0518Y737 .............

12 Klicks

(640

LC4)

 

WP 1418Y750 .............

15 Klicks

(640

LC4 Supermoto)

Compression damping of shock absorber

With the knob 3 the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during compression.

BASIC SETTING:

 

 

 

WP 0118Y734 .............

Position 3

(640

LC4)

WP 0118Y733 .............

Position 4

(640

LC4 Supermoto)

3

Rebound damping of shock absorber

With the setting wheel 4 the degree of damping of the rebound can be adjusted to 11 positions. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding.

 

BASIC SETTING:

 

 

 

 

4

WP 0118Y734 .............

Position 7

(640

LC4)

 

 

WP 0118Y733 .............

Position 8

(640

LC4 Supermoto)

 

 

 

 

 

 

 

WARNING

 

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY

MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

Holding bars

ENGLISH

11

The passenger can hold on to the holding bars on the rear end of the vehicle.

ENGLISH

12

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for initial operation

Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual).

Read these operating instructions carefully before your first ride.

Enter the chassis, engine and key numbers on page 1.

Familiarize yourself with the operating elements.

Adjust the hand brake lever and foot brake lever to your most comfortable position.

Get used to handling the motorcycle on an empty parking lot or open space, 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.

Do not drive along off-road tracks which go beyond your abitily and experience.

Hold the handlebars with both hands and leave your feet on the foot rests while driving.

Remove your foot from the foot brake lever when you are not braking. If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated.

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; distribute 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 with protective clothing and helmet.

Pay attention to running-in procedure.

Running in the LC4 models

Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding against one another for quite some time. Therefore, every engine needs to be broken in. For this reason, during its first 1000 kilometers (620 miles) the engine must not be revved up to its performance limits. The engine speed of 4800 r.p.m. must not be exceeded during the first 1000 kilometers (620 miles). During this break-in time, you should ride your motorcycle in different conditions (roads, easy off-road terrain). The following table shows you the maximum velocity values in the different gears at 4800 r.p.m. as based on the rear wheel transmission ratio of your motorcycle.

ratio

625 LC4

LC4 SUPERMOTO

gear

16:42 Z

17:42 Z

1. G

35 kmh

35 km/h

 

 

 

2. G

50 kmh

55 km/h

 

 

 

3. G

70 kmh

75 km/h

 

 

 

4. G

90 kmh

90 km/h

 

 

 

5. G

100 kmh

100 km/h

 

 

 

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.

 

WARNING

 

WEAR 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 COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING.

DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

– ONLY 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 VEHICLES DRIVING PROPERTIES.

– THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE.

– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PURPOSE, RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN.

– DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED WHEN THE TIRES ARE WARM.

– 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.

– CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS.

DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.

RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR

GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, THE OPERATOR WILL BE BLINDED.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING.

Accessories and payload

Accessory parts and baggage can significantly decrease a motorcycle's driving stability. Please observe the following warnings.

 

WARNING

 

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOU HAVE MOUN- TED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE'S HANDLING, ESPECI- ALLY IN THE MAXIMUM SPEED RANGE.

– NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOUR MOTORCY- CLE IS LOADED WITH CASES OR OTHER BAGGAGE. THEY WILL IMPAIR THE MOTORCYCLE'S HANDLING AT HIGHER SPEEDS AND CAN EASILY CAUSE IT TO GO OUT OF CONTROL

– IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFACTU- RER'S RECOMMENDED MAXIMUM PAYLOAD.

– FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTORCYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR WHEELS AND ON THE LEFT AND RIGHT.

– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND; LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.

– A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING AND CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT YOUR DRIVING SPEED ACCORDINGLY.

DRIVING INSTRUCTIONS

Check the following before each start

When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start.

The following checks should be performed:

1CHECK OIL LEVEL

Insufficient oil results in premature wear and consequently to engine damage.

2FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.

3CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear of chain and chain wheels.

4TIRES

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 deteriorate the driving performance.

5BRAKES

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 indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.

Also check the state of the brake hose and the thickness of the brake linings.

Check free travel at hand brake lever and foot brake lever.

6CABLES

Check correct setting and smooth operation of all control cables.

7COOLING FLUID

Check the level of cooling fluid when the engine is cold.

8ELECTRICAL SYSTEM

Check correct operation of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running.

9LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

10REAR MIRROR

Sit on the motorcycle and check the adjustment of the rear mirror.

ENGLISH

13

1

ENGLISH

2

14

3

6

4

Starting when the engine is cold

1Open the fuel tap 1

2Switch on ignition (turn ignition key 2 into position ).

3Switch on emergency OFF switch 3.

4Switch transmission to idle (green indicator lamp N 4 lights up).

5Operate cold starting device (choke) 5.

6Do not accelerate; operate starter button 6.

7If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly.

8Take the motorcycle off of the main stand or side stand.

WARNING

– TO AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER.

– 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

!

– MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN.

DONT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DONT REV ENGINE WHEN

COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM.

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.

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 „Troubleshooting“ section or contact a KTM dealer.

NOTE LC4 / LC4 SUPERMOTO:

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.

Motorcycles with side stands are also equipped with a safety starting system.

If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop.

Starting when the engine is warm or hot

1Open the fuel tap 1

2Switch on ignition (turn ignition key 2 into position ).

3Switch on emergency OFF switch 3.

4Switch transmission to idle (green indicator lamp N 4 lights up).

5Do not accelerate; operate starter button 6.

6Take the motorcycle off of the main stand or side stand.

What to do when the engine is „flooded”

The throttle must be fully opened when starting. If necessary change sparkplug.

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