KTM 660 SMC 2003 Owner's manual

5 (2)

660 SMC

BEDIENUNGSANLEITUNG

OWNER’S MANUAL

MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES

2003

Art.Nr. 3.210.54 9/2002

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 PRE-

VIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING 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

ENGLISH 2

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 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 become 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

Attachments: Spare parts manual chassis & engine

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION

The KTM 660 SMC is designed and constructed to resist the usual wear and tear of normal use in competitions.

The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

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. An improperly tuned chassis can lead to damage and breakage of the chassis components.

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.

The SMC models are only allowed on public roads in the original homologated (throttled) version. Without this performance restriction (i.e. dethrottled), these models are only allowed to be driven in Supermoto competitions but not on public roads.

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

	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
Indicator lamps.................................................................	6
Electronic speedometer.....................................................	6
Tripmaster switch .............................................................	7
Overview of tripmaster functions ...................................	10
Combination switch........................................................	11
Flasher switch.................................................................	11
Filler cap.........................................................................	11
Fuel tap ..........................................................................	11
Choke ............................................................................	11
Hot start device ..............................................................	12
Shift lever .......................................................................	12
Kickstarter ......................................................................	12
Foot brake pedal ............................................................	12
Handlebar lock ...............................................................	12
Compression damping of fork ........................................	13
Rebound damping of fork ..............................................	13
Compression damping of shock absorber .......................	13
Rebound damping of shock absorber .............................	13
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE...................................................................	14
DRIVING INSTRUCTIONS ..................................................	15
PERIODIC MAINTENANCE-SCHEDULE ..............................	18
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........	20
Removal of seat..............................................................	20
Tool set ..........................................................................	20
Check and adjust steering head bearing .........................	21
Breather plugs front fork ................................................	21
Cleaning the dust sleeves of the telescopic fork ..............	21
Basic suspension setup for the weight of the driver.........	22
Changing the spring preloading of the shock absorber	...24
Checking rubber ring on the WP rear shock absorber .....	24
Lubricate rear suspension linkage ...................................	24
Checking chain tension...................................................	24
Correct chain tension......................................................	25
Chain maintenance.........................................................	25
Chain wear.....................................................................	25
General informations about KTM disc brakes..................	26
Adjusting of free travel at the hand brake lever ..............	27
Checking brake fluid level - front brake ..........................	27
Refilling the front brake fluid reservoir............................	27
Check the front brake pads ............................................	27

Index

	Page
Replacing front brake pads .............................................		28
Check the rear brake fluid level ......................................		28
Refilling the rear brake fluid reservoir .............................		28
Changing the basic position of the brake pedal ..............		29
Checking the rear brake pads .........................................		29
Replacing the rear brake pads.........................................		29
Dismounting and mounting the front wheel ...................		30
Dismounting and mounting the rear wheel.....................		30
Tires, air pressure............................................................		31
Checking spoke tension..................................................		31
Check/set distance of the magnetic sensor .....................		31
Kilometers or miles .........................................................		32
Setting the clock.............................................................		32
Activating/deactivating the display modes......................		32
Replacing headlight lamp/parking light lamp..................		33
Exchanging the brake light and tail light bulb .................		33
Cooling system...............................................................		34
Checking the coolant level..............................................		34
Cleaning air filter ............................................................		35
Exhaust system...............................................................		35
Adjusting the throttle cable ............................................		36
Checking the adjustment of the hand decompression cable		..36
Changing the original position of the clutch lever ...........		36
Checking the oil level of the hydraulic clutch ..................		37
Bleeding of the hydraulic clutch......................................		37
Draining the float chamber of the carburetor..................		37
Carburetor – Adjust idling...............................................		38
Adjusting the mixture control screw ...............................		38
Checking the float level ..................................................		38
Engine oil .......................................................................		39
Checking the engine oil level ..........................................		39
Oil circuit........................................................................		39
Changing the engine oil .................................................		40
Changing and bleeding the microfilter............................		40
Changing oil filter...........................................................		41
TROUBLE SHOOTING........................................................		42
CLEANING..........................................................................		44
CONSERVATION FOR WINTER OPERATION ....................		44
STORAGE ...........................................................................		44
Re-initation after time of storage....................................		44
TECHNICAL SPECIFICATIONS - ENGINE ...........................		46
TECHNICAL SPECIFICATIONS - CHASSIS...........................		48
HEAD WORD INDEX..........................................................		50
WIRING DIAGRAMME ..........................................	APPENDIX

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

	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 is mounted on the right side of the handle bar and
	actuates the front wheel brake.
	The standard position of the hand brake lever can be adjusted with the
	adjusting screw (see maintenance work).

Indicator lamps

The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator.

The blue control lamp 2 lights up when the high beam is on.

ENGLISH

Electronic speedometer

The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move.

The engine must be started in order for the speedometer to be supplied with electricity from the generator. The display is not activated until the front wheel has made 1 revolution (impulse for speedometer).

TEST

All of the display elements will light up for 1 second for the function test.

WS (wheel size)

The display will change and briefly show the diameter of the front wheel in millimeters.

If the front wheel does not turn, the display will automatically change to the SPEED/H mode.

If the front wheel turns, the display will automatically change to the SPEED /ODO mode.

SPEED/H (hours) display mode

When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared.

Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.

SPEED/ODO display mode

The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode.

The information will disappear in the display when the front wheel stops turning for 1 minute.

+ BUTTON

– BUTTON

–

MODE

Tripmaster switch

The switch has 3 buttons: MODE, + (plus) and – (minus).

The switch can also be mounted on the outer end of the handlebar with a clamp (SP.NO. 583.14.069.350).

WARNING

DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT.

Electronic speedometer functions provided by the Tripmaster switch

The display modes on the electronic speedometer will change in the following order. If not, please read the chapter "ACTIVATING AND DEACTIVATING THE DISPLAY MODE."

SPEED/ODO display mode

SPEED displays the speed in KPH or MPH. The displayed figure cannot be cleared.

ODO displays the kilometers or miles traveled. The displayed figure cannot be cleared.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

SPEED/MAX display mode

MAX displays the maximum speed. It is always active.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0

SPEED/LAP display mode

LAP displays the stopped lap time in hours, minutes and seconds.

Starts and stops the stop watch. The lap time is not reset to 0. Stops the running stop watch, stores the lap time and restarts the stop watch. The time is reset to 0. A total of 10 lap times can be stored and read in the SPEED/LAP display mode. To clear all of the stored lap times, hold the MODE button for 3 seconds in the SPEED/LAP mode.

press the MODE BUTTON to change to the next mode

If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped.

press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all stored lap times to 0

LAP/LAP display mode

The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display.

If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped.

Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the stored lap times.

+ BUTTON	changes to the next lap time.
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

ENGLISH 7

ENGLISH 8

SPEED/CLK (clock) display mode

CLK will display time in hours, minutes and seconds.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode.

press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK)

SPEED/H (hours) display mode

Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the SETUP mode (see REVEALING/CONCEALING functions).

SPEED/TRP1 (trip 1) display mode

The TRP1 trip meter is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops. TRP1 is linked to AVS1 and STP1. The calculation of these figures is activated by the first impulse received from the wheel sensor (when the front wheel starts to turn) and stops 3 seconds after the last impulse is received (when the front wheel has stopped).

The TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing 999.9.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode.

press and hold the MODE BUTTON 3 SECONDS to automatically reset the TRP1, AVS1 and STP1 figures to 0.

SPEED/AVS1 (average speed 1) display mode

AVS1 is always active and shows the average speed based on the TRP1 and STP1 figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0.

SPEED/STP1 (stop 1) display mode

STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0.

SPEED/TRP2 (trip 2) display mode

The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook.

TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received.

+ BUTTON increases the TRP2 figure

– BUTTON decreases the TRP2 figure

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset TRP2 to 0

SPEED/AVS2 (average speed 2) display mode

AVS2 shows the average speed based on the TRP2 and STP2 figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 was not stopped after the trip.

+ BUTTON	no function
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

SPEED/STP2 (stop 2) display mode

STP2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing.

Press the MODE button to change to the next mode. The STP2 display will blink in the other modes if STP2 continues to run in the background. To stop STP2, return to the SPEED/STP2 mode and press the + button.

+ BUTTON	starts and stops the stop watch
– BUTTON	no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset STP2 figures to 0

ENGLISH 9

ENGLISH

Standing motorcycle	Driving motorcycle		OVERVIEW OF TRIPMASTER FUNCTIONS

		Display	Press +	Press –	Press MODE	Hold MODE for 3 sec
	X	SPEED / ODO	no function	no function	next display mode	no function

X	X	SPEED / MAX	no function	no function	next display mode	resets MAX to 0

X	X	SPEED / LAP	starts / stops LAP	stops LAP, stores LAP	next display mode	clears all LAP figures
			figure LAP remains	figure, resets LAP to 0

X		LAP / LAP	next figure	no function	next display mode	next display mode

X	X	SPEED / CLK	no function	no function	next display mode	set clock menu

X		SPEED / H	no function	no function	next display mode	display setup menu

X	X	SPEED / TRP1	no function	no function	next display mode	resets TRP1, STP1 and
						AVS1 to 0

X	X	SPEED / AVS1	no function	no function	next display mode	resets TRP1, STP1 and
						AVS1 to 0

X	X	SPEED / STP1	no function	no function	next display mode	resets TRP1, STP1 and
						AVS1 to 0

X	X	SPEED / TRP2	increases TRP2 figure	decreases TRP2 figure	next display mode	resets TRP2 to 0

X	X	SPEED / AVS2	no function	no function	next display mode	next display mode

X	X	SPEED / STP2	starts / stops STP2	no function	next display mode	sets STP2 to 0

C B A

OFF		ON		RES
	RES		RES		RES
	F		F		F
F	U	F	U	F	U
F	E	F	E	F	E
F	E	F	E	F	E
O	L	O	L	O	L
	ON		ON		ON

Combination switch

The light switch has 3 switch positions.

A = Light off

B = Low beam light

C = High beam light

The red short circuit button 1 serves to switch off the engine. Leave the switch pressed, until the engine stops. With the button 2 the horn will sound.

	Flasher switch	ENGLISH
	The flasher switch is a separate unit and is mounted on the left portion of	ENGLISH

	the handlebar.
	The wire harness is designed in a way that whenever you want to use your
	bike off-road, you can dismount the entire turn indicator system without
	affecting the function of the remaining electrical system.
	Flasher left
	Flasher right

Filler cap

To open filler cap: Turn the filler cap counter-clockwise.

To close filler cap: Screw on the filler cap clockwise.

Install tank breather hose 3 without kinks.

Fuel tap

OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the rotating handle 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 tank, approximately 2,5 liters, cannot be tapped until the rotating handle is turned to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too.

Choke

If you pull the choke button 4 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position.

ENGLISH

Hot start device

If you pull the hot start device 1 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean“ fuel-air mixture of the type needed for hot starts.

To deactivate the hot start device, push the hot start button back into its

basic position.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the

2,3,4,5 gears is shown in the illustration. Neutral position 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 foot rest. Its basic position can be adjusted to your seat position (see maintenance work).

Handlebar lock

The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw.

CAUTION

NEVER LEAVE THE KEY INSERTED IN THE LOCK. IF YOU TURN THE STEERING TO THE LEFT

THE KEY COULD GET DAMAGED.

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.

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 1418X738 ..................... 20 clicks

	Rebound damping of fork	ENGLISH
	Hydraulic rebound damping determines the reaction when the fork is	ENGLISH

	rebound. By turning the knob 2, 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 1418X738 ..................... 15 clicks
		13

Compression damping of shock absorber

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

STANDARD ADJUSTMENT:
WP 0118X730 ...................	position 4

Rebound damping of shock absorber

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

STANDARD ADJUSTMENT:
WP 0118X730 ...................	position 8

ENGLISH

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.

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.

– 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.

– THESE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY - NO ADDITIONAL PASSENGER ALLOWED!

– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.

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	660 SMC
gear	16:38 Z

1. G	35 kmh

2. G	55 kmh

3. G	80 kmh

4. G	95 kmh

5. G	110 kmh

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.

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.

ENGLISH

Starting when the engine is cold

1Open the fuel tap 1

2Swing up the side stand

3Put the gear in neutral

4Operate the choke 2

5Go to the left of your motorbike. DO NOT open the throttle, and briskly kick the kickstarter 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 PUSH YOUR FOOT UPWARD WITH
1
1	GREAT VEHEMENCE.

–ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH LESS ENOUGH FORCE AND AN OPENED THROTTLE

INCREASE THE KICK-BACK HAZARD.

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

CAUTION

–BEFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE SIDE STAND.

–DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS

COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED

CYLINDER, IT CAN CAUSE ENGINE DAMAGE.

NOTE:

This motorcycle is equipped with a safety starter 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
3	Starting when the engine is warm or hot
3	1	Open the fuel tap 1
	2	Swing up the side stand
	3	Put the gear in neutral
	4	Push the hot start button 3
	5	Go to the left of your motorbike. DO NOT open the throttle, and briskly
		kick the kickstarter ALL THE WAY.

What to do when the engine is „flooded”

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

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in 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 opening the throttle all the way, turn throttle back to 3/4; the speed will not decreases but the engine will use less fuel.

Only give as much throttle as the engine can handle. Through quick and high reving of throttle, the fuel consumption increases. When 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.

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