KTM 690 LC4 User Manual

690 LC4 SUPERMOTO PRESTIGE

690 LC4 SUPERMOTO

ART. NR. 3.211.147 EN

OWNER’S MANUAL 2007

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. © 2007 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

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 incorpo-

rated 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.

Frame number

Engine number

Key number

Stamp of dealer

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

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

IMPORTANT INFORMATION »

INTENDED PURPOSE

The 690 Supermoto / Prestige is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain.

OWNER'S MANUAL

Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains useful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries. The Manual also contains important information on service and maintenance. In your own interest, pay particular attention to the information marked as follows:

– Ignoring these instructions, can endanger your body and

your life.

– Ignoring these instructions could cause damage to parts

of your motorcycle or that the motor-cycle is not road-safe anymore.

The Owner's Manual corresponded to the latest information available for this model series at the time it was printed. Minor deviations resulting from enhancements to the motorcycle design cannot be entirely precluded. The Owner's Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold.

SERVICE

Observance of the service, maintenance and operating instructions for the engine and chassis specified in the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. Please observe the prescribed breaking-in periods, inspection intervals and service intervals. Strict observance will significantly prolong the service life of your motorcycle.

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.

IMPORTANT INFORMATION »

WARRANTY

The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop. This is the only place that has the qualified technicians and the special tools required for the 690 Supermoto / Prestige. Be sure to have the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty. The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle.

AUTOMOTIVE FLUIDS

The fuels, lubricants and liquids specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule.

SPARE PARTS, ACCESSORIES

For your own safety, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

ENVIRONMENT

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.

Enjoy driving your motorcycle !

KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

INDEX »

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .2

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .6

Chassis number, type label . . . . . . . . . . . . . . . . . . . . . . . . .6

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Clutch lever (690 Supermoto) . . . . . . . . . . . . . . . . . . . . . . .7

Clutch lever (690 Supermoto Prestige) . . . . . . . . . . . . . . . .7

Combined instrument display . . . . . . . . . . . . . . . . . . . . . .8

Function buttons on combined instrument . . . . . . . . . . . . .8

Combined instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Cooling liquid temperature display . . . . . . . . . . . . . . . . . .11

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Emergency OFF tip switch, starter tip switch . . . . . . . . . . .14

Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . . .15

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .18

Compression damping of fork (690 Supermoto Prestige) . . .18

Rebound damping of shock absorber . . . . . . . . . . . . . . . . .19

Damping action during compression of shock absorber

(690 Supermoto Prest) . . . . . . . . . . . . . . . . . . . . . . . . . .19

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Instructions for initial operation . . . . . . . . . . . . . . . . . . . .20

Running in the LC4 engine . . . . . . . . . . . . . . . . . . . . . . . .20

Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . .21

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .22

Check the following before each start . . . . . . . . . . . . . . . .22

Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Fuel, refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .30

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .34

Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . .35

Adjusting compression damping of fork

(690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .35

Adjusting the fork and shock absorber . . . . . . . . . . . . . . .35

Compression damping of shock absorber

(690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .36

Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . . . .37

Adjusting rebound damping of shock absorber . . . . . . . . . .37

Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . .38

Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . .38

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

INDEX »

Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .39

General information on KTM disk brakes . . . . . . . . . . . . . .40

Checking the front brake fluid level

(690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .42

Checking of brake fluid level - front brake (690 Supermoto) 42

Changing the basic position of the handbrake lever . . . . . . .42

Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .43

Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .44

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .44

Dismounting and remounting the front wheel . . . . . . . . . .46

Dismounting and mounting the rear wheel . . . . . . . . . . . . .48

Checking the shock absorption rubbers in the rear hub . . . .50

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Fuses for individual power consumers . . . . . . . . . . . . . . . .55

Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .56

Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .57

Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .57

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Checking the cooling liquid level in the compensating tank .59

Checking the cooling liquid level in the radiator . . . . . . . . .60

Coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . .61

Checking the oil level of the hydraulic clutch

(690 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Changing the original position of the clutch lever . . . . . . . .62

Checking the oil level of the hydraulic clutch

(690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .63

Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . .63

Checking and adjusting the throttle cable play . . . . . . . . . .64

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .65

Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Changing the engine oil and the oil filter, cleaning the

oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .74

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .76

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .82

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

CONSUMER INFORMATION FOR USA ONLY . . . . . . . . . . . . .86

Chassis number, Type label

The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. The type label is located next to the chassis number.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1.

SERIAL NUMBER LOCATIONS »

Clutch lever (690 Supermoto)

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). The clutch is hydraulically actuated and adjusts itself automatically.

Hand brake lever

The hand brake lever [3] is mounted on the right side of the handlebar.The basic position of the handbrake lever can be changed in 4 or 5 steps (see Maintenance work on chassis and engine).

OPERATION INSTRUMENTS »

Clutch lever (690 Supermoto Prestige)

The clutch lever [2] is fitted on the left hand side of the handle bar. The adjusting screw [B] is used to change the original position of the clutch lever (see maintenance work on

chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically.

OPERATION INSTRUMENTS »

Combined instrument

The combined instrument is divided into 4 parts. Function buttons: to select the display modes and basic settings in the display Tachometer: displays the engine speed Indicator lamps: provide additional information on the motorcycle operating condition Display: shows the speed, cooling liquid temperature, time, distance traveled

(ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2), distance traveled since the reserve warning lamp went on (TRIP F)

Function buttons on combined instrument

MODE [1] Briefly press the MODE button to go to the next display mode. The available display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2). The speed, cooling liquid temperature and time are always displayed.

SET [2] Press the SET button to reset trip master 1 or 2 to 0.

The 3rd button is not programmed.

Combined instrument display

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

LENGTH The display will change for 1 second to display the circumference of the front wheel in millimeters. 1870 mm corresponds to a 17" front wheel.

Then the display will change back to the mode that was activated when the ignition was switched off.

OPERATION INSTRUMENTS »

SPEED [1] The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph).

CHANGING THE SPEED DISPLAY FROM KM/H - MPH or MPH - KM/H Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode.

CLOCK [2] The dots between the hours and minutes will blink in the CLOCK display. The clock must be set if the battery was disconnected or if the fuse 2 was blown.

SETTING THE CLOCK Switch on the ignition and select the ODO mode. Press and hold the MODE button while you press the SET button more than 1 second. The time will start to blink. Use the MODE button to set the hours. Use the SET button to set the minutes. Then press the MODE and SET buttons simultaneously.

ODO [3] Displays the total kilometers or miles traveled. This figure will not be cleared if the battery is disconnected.

OPERATION INSTRUMENTS »

TRIP 1 [1] The trip meter 1 is always active and counts up to 999.9. It is used to measure the length of the trip or the distance between 2 refueling stops.

TO RESET TRIP 1 To reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode and press the SET button more than 2 seconds.

Press the MODE button to go to the next display mode.

TRIP 2 [2] The trip meter 2 is always active and counts up to 999.9. It is used just like TRIP 1.

TO RESET TRIP 2 To reset the trip meter 2 to zero, switch on the ignition, select the TRIP 2 display mode and press the SET button more than 2 seconds.

Press the MODE button to go to the next display mode.

TRIP F [3] 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 light up. You will still have enough reserve fuel for at least 30 kilometers. After refueling, it will take approx. 3 minutes for the fuel lamp to go out, TRIP F to automatically reset to 0 and to return to the previous display mode.

NOTE: Press the SET button for 2 seconds to switch off the fuel warning lamp.

OPERATION INSTRUMENTS »

Tachometer

The tachometer [3] shows the engine speed in revolutions per minute. Do not run the engine beyond the orange mark at 7800 rpm. The speed limiter will set in at 8600 rpm, drastically reducing the engine power above this rotational speed.

Cooling liquid temperature display

The temperature display [1] is shown in 12 bars. The more bars that light up, the hotter the cooling liquid. When the upper bar lights up 115°C (239°F), all of the bars will start to blink and the red warning lamp [2] will light up.

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 left radiator is not running – Improper use of the clutch when driving slowly

OPERATION INSTRUMENTS »

Indicator lamps

The green indicator lamp will blink in the blinker rhythm when the blinker is switched on. 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.

The red warning light will light up when the cooling liquid has reached a temperature of approx. 115°C (239°F).

The orange warning lamp will light up when the fuel level has reached the reserve mark. At the same time the display will automatically change to TRIP F (see TRIP F).

The orange warning lamp (fuel injection) briefly lights up when the ignition is switched on. It will go out when the gasoline pressure is high enough. If this warning lamp lights up while driving, a component in the injection system is defective. The error can be identified by means of a blink code (see Trouble shooting).

The red warning lamp will light up if the voltage in the on-board electrics drops below 10 volts. Immediately drive to the nearest authorized KTM workshop and have the electrical system checked.

OPERATION INSTRUMENTS »

Ignition lock

The ignition lock has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, light 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 to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and .

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

The horn is sounded with button [4].

Emergency OFF tip switch, starter tip switch

The emergency off switch [1] 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).

Use the starter tip switch [2] to operate the electric starter.

Filler cap

The filler cap [3] 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.

OPERATION INSTRUMENTS »

Fuel taps

2 fuel taps [4] are mounted on the fuel tank that must be open when the motorcycle is running. The level in the fuel tanks is equalized by means of a connecting hose. The fuel cocks only need to be closed to remove the tank.

Opening the fuel tap: Turn the knob all the way to the left. Closing the fuel tap: Turn the knob all the way to the right.

Seat lock, removing the seat

The seat lock [2] can be locked with the ignition key. To remove the seat, insert the ignition key and turn 45° in a counterclockwise direction. Lift the seat in the back, pull back and lift off.

To mount the seat, attach the seat to the oval head screw [3], lower the seat in the back while sliding it towards the front. Both noses [4] should fit into the frame. Insert the catch bolts [5] in the lock housing and push the seat down in the back until you hear the catch bolts snap into place. Check whether the seat is correctly mounted.

If not correctly mounted, the seat can slip while you are driving and cause you to lose control of your motorcycle.

OPERATION INSTRUMENTS »

Grips

The grips [1] are used to maneuver the motorcycle. If carrying a passenger, the passenger can hold on to the grip during the ride.

OPERATION INSTRUMENTS »

Owner's manual

The vehicle comes with owner's manuals in several languages. Place the owner's manual issued in your language in the protective cover included in the scope of supply and fasten it under the seat (see photo).

Tool set

The tool set [1] is located in the storage compartment under the seat.

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.

OPERATION INSTRUMENTS »

Side stand

Fold the side stand [1] forward to the stop with your foot and put the weight of the motorcycle on the stand. Make sure it is standing securely on a firm surface. The side stand is linked to the safety start system; follow the driving instructions.

Foot brake pedal

The foot brake pedal [2] is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

Footrests

The passenger footrests [3] fold up.

OPERATION INSTRUMENTS »

Compression damping of fork (690 Supermoto Prestige)

The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [1] are located on the fork leg axle passage. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Rebound damping of fork

The fork's damping action during rebound travel (rebound damping) can also be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [2] are located on the upper end of the fork legs. More information is provided in the chapter "Adjusting the fork and shock absorber.“

OPERATION INSTRUMENTS »

Damping action during compression of shock absorber (690 Supermoto Prest)

The shock absorber's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the shock absorber's damping behavior to match your driving style and the payload. The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the movement of the shock absorber and not to the motorcycle's driving speed.

The adjusting screw [1] for the low-speed range can be adjusted with a screwdriver.

The adjusting screw [2] for the high-speed range can be adjusted with a 15 mm socket wrench.

More information is provided in the chapter "Adjusting the fork and shock absorber.“

Rebound damping of shock absorber

The shock absorber's damping action during rebound travel (rebound damping) can also be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screw [3] is located on the bottom of the shock absorber. More information is provided in the chapter "Adjusting the fork and shock absorber.“

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for initial operation

– Make sure the work for the „pre-delivery

inspection“ was performed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

– Read these operating instructions care-

fully before your first ride.

– Enter the chassis, engine and key num-

bers on page 1.

– Familiarize yourself with the operating

elements.

– Adjust the clutch lever, the hand brake

lever, the foot brake lever and the shift lever in the position that is most convenient for you.

– This motorcycle is equipped with a three-

way catalytic converter. Leaded fuel will destroy the converter. Always use unleaded fuel.

– Get used to handling the motorcycle on

an empty parking lot, 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 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 motor-

cycle 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, 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.

– Motorcycles are sensitive to changes in

the weight distribution. Read the section on „Accessories and payload“ when carrying luggage.

– Pay attention to running-in procedure.

Running in the LC4 engine

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 (620 miles). 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 6000 rpm. Once you have run your engine in for 1000 km, you may push it to its 7800 rpm limit , i.e. up to the orange 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.

– 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.

– 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.

– The front and rear wheel are allowed to

be fitted only with tires that have the same profile type.

– The tires must be designed for a

maximum speed of 210 KPH (speed symbol H) and must be authorized by KTM.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

– New tires have a smooth surface, which

– Wheels with a different rim diameter or

other rim width may not be mounted otherwise the vehicle handling will no longer be safe.

– 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.

– The faster you drive, the more sensitive

your motorcycle will be to crosswind and changing road conditions. Your motorcycle can easily go out of control at high speeds.

– 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 on time

so as to ensure optimum vision in any situation. When light shines directly on scratched visor, the operator will be blinded.

– A passenger may only ride on the motor-

cycle if passenger footrests are mounted.

– Never leave your motorcycle without super-

vision 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.

– Never drive faster than 130 kph (80 mph)

if you have mounted accessory parts on your motorcycle. Accessory parts can significantly impair the motorcycle's handling, especially in the maximum speed range.

– Never drive faster than 130 kph (80 mph)

if your motorcycle 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 manufacturer's recommended maximum payload.

– Make sure your luggage does not extend

beyond the silencer, otherwise it may become singed from the heat.

– Make sure your luggage does not cover

the tail light.

– Baggage must be securely and adequately

fastenend; loose baggage will significantly impair driving safety.

– A high payload will change the motorcy-

cle's handling and considerably increase the braking distance; adapt your driving speed accordingly.

– 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

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:

1 FUEL

Check the fuel quantity in the tanks.

2 CHAIN

Check the tension and condition of the chain. A loose chain can fall off the sprockets and a worn-out chain can tear. In both cases this can damage other motorcycle components and cause the motorcycle to go out of control. A chain that is too tight or not greased will cause unnecessary wear to the chain and sprockets.

3 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

4 BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn. If the level of brake fluid falls below the minimum value, this 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.

5 CABLES

Check the throttle cable for correct adjustment and smooth operation.

6 COOLING FLUID

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

7 ELECTRICAL SYSTEM

Start the engine and check the headlight, tail lamp, brake light, turn signals, indicator lamps, horn and emergency-off switch for proper functioning.

8 CHECK OIL LEVEL

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

9 BAGGAGE, PAYLOAD

Never exceed the maximum total weight (350 kg, 773 lbs) and the motorcycle's wheel loads. The maximum total weight is comprised of: – the motorcycle in a running condition and refueled (164 kg, 362 lbs) – the baggage and accessories – the driver and passenger with protective gear and helmet Adapt the tire air pressure and the damping properties of the fork and shock absorber to the motorcycle's total weight. Make sure your luggage is correctly fastened before you drive off.

10 REAR MIRROR

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

DRIVING INSTRUCTIONS »

Starting the engine

1 Switch on emergency OFF switch [1]. 2 Switch on ignition (turn ignition key [2] into position ).

NOTE: You will hear the operation of the fuel pump for approx. 2 seconds after switching on

the ignition. The instrument cluster function test is also performed at this time. 3 Switch transmission to idle (green indicator lamp N [3] lights up). 4 Do not accelerate; operate starter button [4]. Do not actuate the starter control until the

instrument cluster function test is completed. 5 Take the load off the side stand and fold the side stand all the way up.

– Do not start the engine and allow it to idle in a closed room. Exhaust fumes are poison-

ous and can cause loss of consciousness and death. Always provide adequate ventila-

tion while the engine is running.

– Never operate the motorcycle with a run-down battery or without the battery. This can

damage the electronic components or safety equipment in either caseand the motorcy-

cle will no longer be roadworthy.

– If you accelerate while starting, the engine management will not inject any fuel and the

engine will not start. Do not accelerate while starting!

– Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try-

ing 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 let the engine warm up before and refrain from driving with full load until the

engine is warm.

DRIVING INSTRUCTIONS »

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 dis-

charged

– 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:

– whether you accelerated while starting – whether the FI indicator lamp is blinking

– if yes, check Troubleshooting - Blink

codes table

– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank – if sufficient fuel is in the tank, pro-

ceed as described in the „Troubleshooting“ section or contact a KTM dealer.

NOTE: This motorcycle is equipped with a safety starting system. The engine can only be started if the transmission is in neutral or the clutch lever is pulled. If the side stand is folded down, the engine can only be started if the transmission is in neutral or the clutch lever is pulled. The engine will stall if a gear is

engaged and the clutch lever is released with the side stand folded down.

Starting off

Pull the clutch lever and engage 1st gear. Slowly release the clutch lever while you gently accelerate.

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 carefully open throttle. Do not shift gears and accelerate carefully in curves. Only accelerate to the extent that road and weather conditions allow. Be especially careful when you accelerate in curves. Abrupt opening of the throttle can cause the motorcycle to go out of control and also increases fuel 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.

Stop immediately if the FI indicator lamp lights up while driving. The FI indicator lamp will start blinking as soon as the transmission is in neutral. The rhythm of the blinking lamp will let you determine the two-digit „blink code“, e.g.: Blink code 24: FI blinks 2x long, 4x short, pause, Blink code 06: FI blinks 6x short, pause The blink code will indicate which component is defective (see Troubleshooting). This makes it possible to pinpoint the defect if a diagnostic tool is unavailable.

– Avoid abrupt load changes while riding

around bends and on wet or slippery ground. Otherwise you might easily lose control over your motorcycle.

– While riding your motorcycle, never switch

the ignition lock to positions and .

– Do not try to change the settingsof the

combined instrument while driving. Your attention will be distracted from the traffic and this may cause you to lose control of your motorcycle.

– The passenger must hold on to the driver

or the grab handles during the ride and keep his feet on the passenger footrests.

– Regularly make sure that the baggage

and cases are tightly fastened.

DRIVING INSTRUCTIONS »

– 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.

– 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. The engine has reached operating temperature as soon as the 5th bar on the temperature indicator lights up.

– 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.

– Never use your motorcycle without an air

filter. Otherwise dust and dirt may enter the engine and cause increased wear.

– The red coolant warning lamp lights up

when the coolant temperature has reached 115°C (239°F). Possible causes for the increase in temperature: – low driving velocity and high load

situation in high air temperatures

– level of coolant in the system is insuf-

ficient – fan at radiator is not running –

improper use of the clutch while driving

at low velocities Let the engine cool down. Meanwhile, check whether any cooling liquid is leaking out of the motorcycle. Check the cooling liquid level in the radiator (not only in the compensating tank). - CAUTION SCALDING HAZARD! Do not drive on, until there is sufficient liquid in the coling system.

– In the event that, while riding on 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. Carefully apply the brakes on sandy, wet or slippery surfaces. Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. Always finish braking before you enter a curve. 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.

– In the rain, or after the motorcycle has

been washed, braking action may be delayed due to wet brake discs. First, the brakes must be braked dry.

– On salt-sprayed or dirty roads brake action

may be delayed as well. First, the brakes must be braked clean.

– Remember that the stopping distance

will be longer if you are carrying a passenger or baggage.

– When you brake, the brake discs, brake

pads, brake caliper and brake fluid heat up. The hotter these parts get, the weaker the braking effect. In extreme cases, the entire braking system can fail.

– If the resistance in the hand brake lever

or foot brake pedal feels „spongy“ (too much play), 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.

+ 63 hidden pages