KTM 640LC4 DukeII 2003 Service Manual

640 DUKE II

BEDIENUNGSANLEITUNG

OWNER’S MANUAL

MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES

2003

Art.Nr. 3.210.58 2/2003

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
	ENGLISH	time to this task. Only by doing so will you learn how to tune your motorcycle to your
		specific needs and how to protect yourself against injury. Besides, this manual contains
		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
		work on the chassis and engine" must be performed. If maintenance work should

2become necessary during a competition it should be performed by a trained mechanic. KTM 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 DUKE 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.

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
Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .6
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .6
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .6
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .6
Ignition lock with 3 switch positions . . . . . . . . . . . . .	. . .6
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .	. . .7
Starter tip switch, emergency OFF tip switch, light switch 7
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .7
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .8
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .8
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .8
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .8
Compression damping of fork . . . . . . . . . . . . . . . . .	. . .9
Rebound damping of fork . . . . . . . . . . . . . . . . . . . .	. . .9
Compression damping of shock absorber . . . . . . . . .	. . .9
Rebound damping of shock absorber . . . . . . . . . . . .	. . .9
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .9
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .10
Instructions for initial operation . . . . . . . . . . . . . . . .	. .10
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .10
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .11
Check the following before each start . . . . . . . . . . .	. .11
Starting when the engine is cold . . . . . . . . . . . . . . . .	. .12
Starting when the engine is warm . . . . . . . . . . . . . .	. .12
What to do when the engine is „flooded” . . . . . . . .	. .12
Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . .	. .13
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .13
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .13
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .13
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .	. .14
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .14
Activating the ignition curve for low-octane fuel . . . . .15
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .	. .16
MAINTENANCE WORK ON CHASSIS AND ENGINE . . .	. .18
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . .	. .18
Supporting strap for the passenger . . . . . . . . . . . . . .	. .18
Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .18
Checking and adjusting the steering head bearing . . .	. .19
Bleeder screw front fork . . . . . . . . . . . . . . . . . . . . . .	. .19
Cleaning the dust sleeves of the telescopic fork . . . .	. .19
Changing the spring preload of the shock absorber	. . .20
Checking the rubber ring of the rear shock absorber	. .20
Lubricating the shock absorber linkage . . . . . . . . . . .	. .20
Checking chain tension . . . . . . . . . . . . . . . . . . . . . .	. .21

		Page
Correcting chain tension . . . . . . . . . . . . . . . . . . .	. .	. .	.21
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	21
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	22
Maintaining chain tension eccentrics . . . . . . . . . .	. .	. .	22
General information about KTM disc brakes . . . . .	. .	. .	23
Changing the basic position of the handbrake lever		. . .24
Checking of brake fluid level - front brake . . . . . .	. .	. .	24
Refilling the front brake fluid reservoir . . . . . . . . . .	. .	. .	24
Checking the front brake pads . . . . . . . . . . . . . . .	. .	. .	24
Changing the basic position of the foot brake pedal		. . .25
Checking the rear brake fluid level . . . . . . . . . . . .	. .	. .	25
Refilling the rear brake fluid reservoir . . . . . . . . . .	. .	. .	25
Checking the rear brake pads . . . . . . . . . . . . . . . .	. .	. .	25
Dismounting and mounting the front wheel . . . . .	. .	. .	26
Dismounting and mounting the rear wheel . . . . . .	. .	. .	26
Checking the damping rubbers in the rear wheel	. . . . .27
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	28
Charging the battery . . . . . . . . . . . . . . . . . . . . . .	. .	. .	28
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	29
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	29
Opening the headlight mask . . . . . . . . . . . . . . . .	. .	. .	29
Headlight range adjustment . . . . . . . . . . . . . . . . .	. .	. .	30
Headlight - replacing the bulbs . . . . . . . . . . . . . . .	. .	. .	30
Parking light - replacing the bulb . . . . . . . . . . . . .	. .	. .	30
Flasher - replacing the bulbs . . . . . . . . . . . . . . . . .	. .	. .	30
Stop light and tail light - replacing the bulb . . . . .	. .	. .	31
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	31
Checking the cooling liquid level . . . . . . . . . . . . .	. .	. .	32
Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	32
Changing the original position of the clutch lever	. . . . .33
Checking the oil level of the hydraulic clutch . . . .	. .	. .	33
Checking and adjusting the choke cable play . . . .	. .	. .	33
Checking the adjustment of the hand decompression cable *			33
Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	34
Draining of float chamber of the carburetor . . . . .	. .	. .	34
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	34
Checking the engine oil level . . . . . . . . . . . . . . . .	. .	. .	34
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	35
Oil and screen filter change, bleeding of the oil system			.35
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . .	. .	. .	36

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .40

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Re-initiation after time of storage . . . . . . . . . . . . . . . . .40

TECHNICAL DATA – ENGINE 640 DUKE II 2003 . . . . . .41

TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2003 .42

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . . . .appendix

A

2

SERIAL NUMBER LOCATIONS

Chassis number

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

Engine number, engine type

The engine number and engine type are stamped on the right hand side of the engine below the engine sprocket. Write the number into the box on page no 1.

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1 is fitted on the left hand side of the handle bar. 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.

ENGLISH 5

Choke lever

When the choke lever 3 is pulled backwards, a bore is opened in the carburetor which enables the engine to draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. When the choke lever is

3 pushed forward as far as it will go, the bore will be closed again. In this position the choke cable must have a play of approx. 2 mm.

1

ENGLISH							B
					2
6			C

Hand brake lever

The hand brake lever 1 is mounted on the right side of the handlebar.The basic position of the handbrake lever can be changed in 4 steps (see Maintenance work on chassis and engine).

Speedometer

The mileage indicator A in the speedometer 2 indicates overall mileage. The day mileage indicator B can be set to 0 by means of the setting wheel C. Turn the setting wheel forward until only zeros can be seen in the display.

Tachometer

The tachometer 3 shows the engine speed in revolutions per minute (rpm). Do not push the engine into the orange zone, which begins at 8500 rpm.

3

	Indicator lamps
	The green indicator lamp flashes when the flasher light is working in
	the same rhythm as the flasher light. Faster flashing of the flasher
	control lamp indicates a defect bulb
	The blue indicator lamp lights up when the high beam is on.
	The green indicator lamp lights up when the neutral gear is selected
	The red cooling liquid temperature warning lamp lights up as soon
	as the cooling liquid has reached a temperature of approximately
	110° C (230° F).
	Ignition lock with 3 switch positions
	Switch positions of ignition lock 4:
	Ignition off, (engine can't be started)
	Ignition on, (engine can be started)
	Ignition off, handlebar blocked
4	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 .

	1	Combination switch
		The rocker switch LIGHTS 1 actuates the high beam or low beam.
		= High-beam light
		= Low-beam light
		The indicator switch 2 returns to central position after actuation.
		Press flasher switch towards switch housing to switch off the flasher.

The horn is sounded with button 3.

4

The light signal (high beam) is actuated with button 4.

4

2

Starter tip switch, emergency OFF tip switch, light switch

Use the starter tip switch 5 to operate the electric starter.

6

The light switch has 3 positions:

= Light off

= Parking light on

= Headlight on

The emergency off switch 6 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).

ENGLISH 7

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.

7

	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
	8

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.

!

CAUTION

!

THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE.

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. The basic position can be adjusted to the seat position (see maintenance work).

1

2

3

4

5

Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.

The damping rate of the compression damping mechanism can be readjusted at the adjusting screws 1 located at the fork leg. Turn it clockwise to increase damping, and counterclockwise to reduce damping during compression.

STANDARD ADJUSTMENT

–turn adjusting screw clockwise as far as it will go

–turn it back by as many clicks as are specified for the relevant type of fork

WP 0518X732 . . . . . . . . . 14 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw 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.

STANDARD ADJUSTMENT

–turn adjusting screw clockwise as far as it will go

–turn it back by as many clicks as are specified for the relevant type of fork

WP 0518X732 . . . . . . . . . 16 clicks

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 rcompressing.

STANDARD ADJUSTMENT:

WP 0118X728 . . . . . . . . .position 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.

STANDARD ADJUSTMENT:

WP 0118X728 . . . . . . . . .position 5

Seat lock

The seat is secured by the lock on the side of the seat 5

ENGLISH 9

ENGLISH

10

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 the entire manual carefully before your first drive.

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

–Familiarize yourself with the operating elements.

–Adjust the foot brake pedal and the hand brake lever to the most comfortable positions 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.

–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 overheated.

–You may only be accompanied by a passenger if your motorcycle is fitted and registered for such purposes. The passenger must hold on to the supporting strap or the driver and keep his feet on the passenger footrests throughout the ride.

–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.

–New tires have a smooth surface and must be run in. For this purpose, carefully ride the motorcycle at moderate speed, tilting the vehicle at different angles so that the surface is evenly roughened. Tires will not display their full grip characteristics before they are properly run in.

–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 and passenger with protective clothing and helmet.

–Pay attention to running in instructions.

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 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.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

–DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–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 VEHICLE’S DRIVING PROPERTIES.

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

– 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.

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

–DRIVE CAREFULLY ON UNKNOWN ROADS

–REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY

OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, YOU WILL BE PRACTICALLY BLIND.

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

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 1000 kilometers. The vehicle must be run in at low, changing performance level for the first 1000 KM (620 miles). The maximum number of revolutions per minute must not go exceed 4800 rpm. Once you have run your engine in for 1000 km (620 mi), you may push it to its 8500 rpm limit , i.e. up to the red zone indicated in the tachometer. Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine.

DRIVING INSTRUCTIONS

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 performing 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.

2FUEL

Check that there is sufficient fuel in the tank.

3CHAIN

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.

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 reduce the driving performance.

5BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. 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 garage, as complete failure of the braking system can be expected.

Also check the state of the brake hoses and the thickness of the brake linings. Brake linings measured at their thinnest point should not be less than 1 mm since extremely worn linings can lead to brake failure.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY” (NOT ENOUGH RESISTANCE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

6CABLES

Check correct setting and easy running of all control cables.

7COOLING LIQUID

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

8ELECTRICAL SYSTEM

Check correct functioning of headlamps, parking light, tail-light, brake light, flashers, indicator lamps and horn while the engine is running.

9LUGGAGE

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

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12

								Starting when the engine is cold
								1	Open the fuel tap.
			1					2	Turn on the ignition.
								3	Switch the gear to neutral (green lamp 1 lights).
								4	Turn on the emergency OFF switch 2.
								5	Operate the choke lever 3.
								6	Operate the starter button 5 without 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 sidestand 4.
								9	Switch on the light before setting off.
										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	!
					2			–	MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5
									SECONDS BEFORE TRYING AGAIN.
								–	DON’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 STAR-
						5		TER TIP SWITCH:

–Check if the ignition is on

–whether the emergency OFF switch

–Check if the emergency off switch 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.

								WARNING
	3
						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.
						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.
						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.
						NOTE:
		4
						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
		6
						1	Open the fuel tap.
						2	Turn on the ignition.
						3	Switch the gear to neutral (green lamp 1 lights).
						4	Turn on the emergency OFF switch 2.
						5	Operate the starter button 5 without accelerating.
						6	Swing up the sidestand 4.
						7	Switch on the light before setting off.

What to do when the engine is „flooded”

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

Kickstart instructions

Be sure to kick up the side stand before you start the engine to avoid any damage.Start as described above, then push the kickstarter hard all the way.

WARNING

– IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE.

– ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED THROTTLE GRIP INCREASE THE KICK- BACK HAZARD.

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

BEFORE YOU START OFF, CHECK THAT THE SIDE STAND HAS BEEN SWUNG RIGHT UP TO THE TOP. IF 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

– AVOID ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY ROADS. OTHERWISE, THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL.

– NEVER TURN THE IGNITION KEY TO POSITION OR WHILE THE MOTORCYCLE IS MOVING.

– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.

– A BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS STABILITY.

!

CAUTION

!

– HIGH 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.

–SHIFT TO THE NEXT HIGHER GEAR BY 8500 RPM AT THE LATEST. ENGINE SPEEDS IN THE RED RANGE MUST STRICTLY BE AVOIDED.

–NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A

LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

– LONG WHEELIE DRIVING CAUSES THE OIL PRESSURE TO DROP. THE OIL PRESSURE WILL AUTOMATICALLY INCREASE AS SOON AS YOU DRIVE ON NORMALLY. DOING WHEELIES FOR A LONG TIME WILL DAMAGE YOUR ENGINE.

– 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.

– IN 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

– DELAYED BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE. IN THIS CASE, REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY.

– DELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY ROADS. IN THIS CASE, REPEATEDLY APPLY THE BRAKES TO REMOVE THE DIRT.

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEA- KER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL.

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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

– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK ABSOR- BERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER OPERA- TING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED.

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

	!	CAUTION	!
–	PARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD
	GROUND, LEVEL SURFACE) AND CAN’T TIP OVER.
–	CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CARBURETOR

CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE.

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.

NOTE REGARDING THE SIDE STAND:

Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways. Make sure that the ground is solid and that your motorcycle is standing securely. Just in case, you can shift into first gear.

!

CAUTION

!

THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE. THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTORCYCLE, THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND.

35 mm

Refueling

In the condition at delivery, the LC4 engine requires leaded or unleaded premium-grade fuel with at least 95 octane (ROZ).

If this type of fuel is not available it is easy to change over to the pre-pro- grammed ignition curve for 80 - 94 octane (ROZ) (see activating the ignition curve for low-octane fuel).

!

CAUTION

!

USE LEADED OR UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE DAMAGE WILL OCCUR.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR’S ADVICE IMMEDIATELY.

Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).