KTM 950 Adventure 2003 Owner's manual

BEDIENUNGSANLEITUNG

OWNER`S MANUAL
MANUALE D`USO
MANUEL D`UTILISATION
MANUAL DE INSTRUCCIONES

ART.NR: 3.210.59

950ADVENTURE2003

ENGLISH

1

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

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 mainten-

ance, 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.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

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

. I

TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

.

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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 by an authorized KTM workshop 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.
The designations "left, right, front, rear“ always refer to the direction of travel.

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.

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

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3

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

IMPORTANT LIMITED WARRANTY AND

LIMITED GUARANTEE INFORMATION

The KTM 950 Adventure models are designed to withstand normal use on
roads and easy terrain (unpaved 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 described in the "Lubrication and maintenance schedule“
must be performed by an authorized KTM workshop that can verify having
attended the respective training programs. Only these workshops will have
trained personnel qualified to service the 950 Adventure. The service work
must be recorded in the service manual, otherwise the warranty will become
null and void.

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.

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4

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .5

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Multi-functional digital speedometer . . . . . . . . . . . . . . . .6

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Setting options in the display . . . . . . . . . . . . . . . . . . . . . .7

Cooling liquid temperature display . . . . . . . . . . . . . . . . .8

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Emergency OFF tip switch, light switch, starter tip switch . . .9

Storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . .10

Filler caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Compression damping of fork . . . . . . . . . . . . . . . . . . . .11

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .11

Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . .12

Damping action during compression of shock absorber . . .12

Rebound damping of shock absorber . . . . . . . . . . . . . .12

Shock absorber's preload adjuster . . . . . . . . . . . . . . . . .12

Baggage carrier plate . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Instructions for initial operation . . . . . . . . . . . . . . . . . .14

Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . . .14

Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . .14

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .15

Check the following before each start . . . . . . . . . . . . .15

Starting when the engine is cold . . . . . . . . . . . . . . . . . .16

Starting when the engine is warm or hot . . . . . . . . . . .16

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . .17

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .20

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .22

Removing and remounting the seat . . . . . . . . . . . . . . .22

Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Adjusting the fork and shock absorber . . . . . . . . . . . .23

Adjusting compression damping of fork . . . . . . . . . . . .23

Adjusting rebound damping of fork . . . . . . . . . . . . . . .23

Adjusting the spring preload on the fork . . . . . . . . . . .23

Compression damping of shock absorber . . . . . . . . . . .24

Rebound damping of shock absorber . . . . . . . . . . . . . .24

Adjusting the preload of the shock absorber . . . . . . . . .25

Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . .25

Cleaning the dust sleeves of the telescopic fork . . . . . .25

Checking the chain tension . . . . . . . . . . . . . . . . . . . . .25

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .26

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Checking the chain for wear . . . . . . . . . . . . . . . . . . . . .26

General informations about KTM disc brakes . . . . . . . .27

Adjusting of free travel at the hand brake lever . . . . . .28

Checking of brake fluid level - front brake . . . . . . . . . .28

Refilling the front brake fluid reservoir . . . . . . . . . . . . .28

Checking the front brake pads . . . . . . . . . . . . . . . . . . .28

Changing the basic position of the foot brake lever . . . .29

Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .29

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .29

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .29

Dismounting and mounting the front wheel . . . . . . . . .30

Dismounting and mounting the rear wheel . . . . . . . . . .31

Checking the shock absorption rubbers in the rear hub . . . . . .31

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .32

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Demounting and mounting the battery . . . . . . . . . . . . .33

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . .33

Connecting the battery jumper cable . . . . . . . . . . . . . .33

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Fuses for individual current consumers . . . . . . . . . . . . .34

Replacing the headlight lamps . . . . . . . . . . . . . . . . . . . .35

Adjusting the headlight range . . . . . . . . . . . . . . . . . . . .36

Replacing the brake and tail light bulbs . . . . . . . . . . . .36

Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . .36

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Checking the cooling liquid level in the compensating tank . . .37

Checking the cooling liquid level in the radiator . . . . . .38

Changing the original position of the clutch lever . . . . .38

Checking the oil level of the hydraulic clutch . . . . . . . . .38

Checking and adjusting the throttle cable play . . . . . . .38

Checking and adjusting the choke cable play . . . . . . . .39

Adjusting the engine idle speed . . . . . . . . . . . . . . . . . . .39

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Checking the engine oil level . . . . . . . . . . . . . . . . . . . .39

Changing the engine oil and the oil filter, cleaning

the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Activating the ignition curve for low-octane fuel . . . . .43

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .46

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

RE-INITIATION AFTER TIME OF STORAGE . . . . . . . . .46

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .47

TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . . .49

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . .APPENDIX

INDEX

Page Page

ENGLISH

5

Chassis number

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

Engine number, engine type

The engine number and engine type are embossed in the engine case near
the shift lever. Write this number into the relevant area on page 1.

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

Choke lever

If the choke lever 2 is pulled backwards, a bore in the carburetors will be
opened in the carburetor through which the engine may draw in additional
fuel. This produces a „rich“ fuel/air mixture necessary for cold start. The
fuel quantity and thus the engine speed are determined by the choke lever
position.
At temperatures over 5°C (41°F) it will suffice to pull the choke lever half
way out. At temperatures below 5°C (41°F) the choke lever should be pul­led all the way out. The hole is closed again by pushing the choke lever all
the way back in.

Hand brake lever

The hand brake lever 3 is mounted on the handlebars on the right and
actuates the front wheel brake. The adjusting screw

B can be used to

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

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

A

2

1

3

B

ENGLISH

6

Multi-functional digital speedometer

The universal instrument is divided into 3 parts.
Use the MODE and SET

1 button to change the display and the basic set-

tings in the display.
Display

2 shows all of the information that may be of interest to you.

5 display modes can be selected with the MODE button.

The indicator lamps

3 provide additional information on the motorcycle's

running condition.

Display

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

WS (wheel size)
The display will change and show the diameter of the front wheel in inches
for 1 second (WS = wheel size).
Then the CLOCK mode will be displayed, or the mode that was active
when the ignition was switched off.

CLOCK
You will recognize the CLOCK display by the blinking dots between the
hours and minutes. It displays the speed, temperature of the cooling liquid
and the clock.
To switch to the next display mode, press the MODE button.

ODO
The speed, temperature of the cooling liquid and the total kilometers or
miles traveled are shown in the ODO mode.
To switch to the next display mode, press the MODE button.

TRIP 1
The TRIP 1 mode shows the speed, the temperature of the cooling liquid
and the trip odometer 1.
To switch to the next display mode, press the MODE button.

TRIP 2
The TRIP 2 mode shows the speed, the temperature of the cooling liquid
and the trip odometer 2.
To switch to the next display mode, press the MODE button.

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

1

2

3

TEST

WS

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

ENGLISH

7

Setting options in the display

KILOMETERS OR MILES.
You can have the speed and distance shown in kilometers or miles in the
display. The display can be adapted to the respective country on long­distance trips.
To switch from kilometers to miles, switch on the ignition and press the
MODE

1 button for approx. 10 seconds. The km/h display will switch to

mph. The speed and the stored distances will be converted and displayed in

miles.
To return to kilometers, proceed as described above.

CLOCK
Switch on the ignition and change to the CLOCK mode.
Simultaneously press MODE

1 and SET 2. The numbers on the clock will

start to blink. Use the MODE button to set the hours and the SET button to
set the minutes.
The press the MODE and SET buttons simultaneously.

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

TRIP 1
The trip meter 1 runs continuously and counts up to 999.9. It can be used
to measure the length of a certain route on a trip or the distance between
two refueling stops.
To return the trip meter 1 to zero, switch on the ignition, change to the
TRIP 1 mode and press the SET button.

RESETTING TRIP 2
The trip meter 2 runs continuously and counts up to 999.9. It can be used
similarly to TRIP 1 or together with a switch available as an accessory (see
below) for trips according to a roadbook.
To return the trip meter 2 to zero, switch on the ignition, change to the
TRIP 2 mode and press the SET button.

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

TRIP F
When the fuel level reaches the reserve mark, the display will automatically
switch to TRIP F and begin to count (no matter which display mode was
active before). At the same time, the fuel warning lamp will start to blink.
You will still have enough reserve fuel for aprox 50 kilometers (30 miles).
After refueling, it will take approx. 3 minutes for TRIP F to automatically
reset to 0 and return to the previous display mode.

10 sec

1

1

2

2

2

ENGLISH

8

Cooling liquid temperature display

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

2 will light up.



WARNING



POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED WARNING LIGHT

FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP

:

– D

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

– NOT ENOUGH COOLING LIQUID IN THE SYSTEM
– T

HE VENTILATOR ON THE RADIATOR IS NOT RUNNING

– IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY

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. 120°C (248°F).

The orange warning light will start to blink 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 red warning lamp lights up when the ignition is switched on
but the engine is not running. When the engine is started, the war­ning lamp will go out as soon as the oil pressure is high enough.

This indicator lamp has no function.

Tachometer

The tachometer shows the engine speed in revolutions per minute. Do not
run the engine beyond the black mark at 9500 rpm.
The speed limiter will set in at 9600 rpm, drastically reducing the engine
power above this rotational speed.

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

1

2

ENGLISH

9

Ignition lock

The ignition lock 1 has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, (engine can be started)

Ignition off, handlebar blocked
To switch the ignition to position turn the ignition key to position

and firmly press it into the
lock. Turn the handlebar all the way to the left, then turn the ignition
key to the left.

The ignition key can be withdrawn in position and .

Combination switch

The rocker switch LIGHTS 2 actuates the high beam or low beam.

= High-beam light

= Low-beam light

The light signal (high beam) is actuated with button

3.

The indicator switch

4 returns to central position after actuation.

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

The horn is sounded with button

5.

Emergency OFF tip switch, light switch, starter tip switch

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).

The light switch

7 has 3 positions:

= Light off

= Parking light on

= Headlight on

Use the starter tip switch

8 to operate the electric starter.

7

8

6

1

2

3

4

2

5

ENGLISH

10

Storage compartment

A storage compartment is located under the seat to hold small, frequently
used items.
To open, turn the quick release

1 approx. 180° in a counterclockwise

direction and lift the cover. To lock, close the cover, insert the quick release
in the dolly and turn 180° in a clockwise direction.

Filler caps

The 950 Adventure has 2 separate fuel tanks.
Both filler caps

2 can be locked and are equipped with a tank vent system.

To open, insert the ignition key, turn 45° in a clockwise direction and fold
up the filler cap.
The ignition key can be pulled out to open the other filler cap. Simply press
on the filler cap to close.

Seat lock

The seat is unlocked by inserting the ignition key in the lock 3 on the side
and turning the key in a counterclockwise direction. See "Maintenance
Work" to remove and remount the seat.

Fuel taps

The 950 Adventure is equipped with 3 fuel taps which only need to be clo­sed to remove the fuel tank.
Fuel cannot flow to the carburetors if the fuel pump is not running, so the
fuel tap

4 does not need to be closed when the motorcycle is switched

off.

Both fuel taps

5 must be open when the motorcycle is running. The level

in the fuel tanks is equalized by means of a connecting hose.

1

2

3

4

5

5

ENGLISH

11

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.

Side stand

The side stand 1 is coupled with a safety starter system. Pay attention to
Driving Instructions.

NOTE:
A center stand is available as an accessory from your authorized KTM
workshop. The side stand does not need to be removed.

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).

Compression damping of fork

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

4 are located under the cap 3 on the lower end of

the fork legs.
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

5 are located on the upper end of the fork legs.

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

2,3,4,5,6

N

1

1

2

3

4

5

5

ENGLISH

12

Spring preload of the fork

The fork's preload can be adjusted by means of the adjusting screws 1.
More information is provided in the chapter "Adjusting the fork and shock
absorber.“

Damping action during compression of shock absorber

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

2 for the low-speed range can be adjusted with a

screwdriver.

The adjusting screw

3 for the high-speed range can be adjusted with a

17 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

4 is located on the bottom of the shock absorber.

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

Shock absorber's preload adjuster

The shock absorber's preload adjuster is infinitely variable by means of the
hand wheel 5. This allows the shock absorber to be adapted to match your
body weight and the payload.
The hand wheel can be swung out to make adjustments.

2

3

4

5

1

ENGLISH

13

Baggage carrier plate

The base plate for your choice of case system can be attached to the bag­gage carrier plate

1.



WARNING



–D

O NOT LOAD MORE THAN 8 KG ON THE TRUNK CARRIER RACK.

–OBSERVE THE BAGGAGE MANUFACTURER'SINSTRUCTIONS.

Grips

The passenger can hold on to both grab handles 2.

Footrests

The passenger footrests 3 fold up.

1

2

2

3

ENGLISH

14

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.
– This motorcycle is equipped with 2 catalytic converters.

Leaded fuel will destroy the catalytic converters. Please use

unleaded fuel only.
– Get used to handling the motorcycle on an empty parking

lot, before starting on a longer drive. Also try to drive as slo-

wly 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 changes in the weight

distribution. Read the section on "Accessories and payload“

when carrying luggage.
– Pay attention to running-in procedure.

Running in the LC8 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 6500 rpm. Once you have run your engine in for
1000 km, you may push it to its 9500 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.



WARNING



–W

EAR 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 COLO

-

RED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE.

Y

OUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING.

–DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE

.

–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

.

–T

HE 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 240 KPH

(SPEED SYMBOL V) AND MUST BE AUTHORIZED BY KTM.
–D

O NOT EXCEED THE RESPECTIVE MAXIMUM SPEED FOR TIRES

DESIGNED WITH A SPEED INDEX OF LESS THAN

"V“ (240 KPH).

A

STICKER SHOWING THE MAXIMUM SPEED MUST BE AFFIXED TO THE

MOTORCYCLE WITHIN THE DRIVER

'S FIELD OF VISION.



WARNING



–NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS

THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP

. FOR THIS PURPOSE,

RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE
FIRST

200

KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT DIFFE-

RENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED. TIRES
WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE
PROPERLY RUN IN

.

–WHEELS WITH A DIFFERENT RIM DIAMETER OR OTHER RIM WIDTH

MAY NOT BE MOUNTED OTHERWISE THE VEHICLE HANDLING WILL NO
LONGER BE SAFE

.

–O

BSERVE 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

.

–C

HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

–D

RIVE 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

. W

HEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

GOGGLES

, THE OPERATOR WILL BE BLINDED.

–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

.

Accessories and payload

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



WARNING



–NEVER DRIVE FASTER THAN 130 KPH (80 MPH) IF YOU HAVE MOUN-

TED ACCESSORY PARTS ON YOUR MOTORCYCLE

. ACCESSORY PARTS

CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE

'S HANDLING, ESPECI-

ALLY IN THE MAXIMUM SPEED RANGE.

– N

EVER DRIVE FASTER THAN

130 KPH

(80 MPH) IF YOUR MOTORCY-

CLE IS LOADED WITH CASES OR OTHER BAGGAGE. THEY WILL IMPAIR
THE MOTORCYCLE

'S HANDLING AT HIGHER SPEEDS AND CAN EASILY

CAUSE IT TO GO OUT OF CONTROL

–IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFACTU-

RER'SRECOMMENDED MAXIMUM PAYLOAD.

–F

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

.

–B

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

.

–A

HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING AND

CONSIDERABLY INCREASE THE BRAKING DISTANCE

; ADAPT YOUR

DRIVING SPEED ACCORDINGLY

.

ENGLISH

15

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

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.

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 adjustment and smooth operation of the throttle cables and
the choke cable.

6 COOLING FLUID

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

7 ELECTRICAL SYSTEM

Start the engine and check the headlight, taillight, brake light, turn
signal, indicator lamps and horn 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 (400 kg, 883 lbs) and the
motorcycle's wheel loads. The maximum total weight is comprised of:
– the motorcycle in a running condition and refueled (220 kg, 485 lbs)
– the baggage and accessories
– the driver and passenger with protective gear and helmet
Adjust the tire inflation pressure as well as the preload and damping pro­perties of the fork and shock absorber to the total weight.



WARNING



N

EVER 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

.

DRIVING INSTRUCTIONS

ENGLISH

16

Starting when the engine is cold

1 Switch on emergency OFF switch 1.
2 Switch on ignition (turn ignition key

2

into position ).
NOTE:
Usually the operating noise of the fuel pump can briefly be heard after
the ignition is switched on.

3 Switch transmission to idle (green indicator lamp N

3

lights up).

4 Operate cold starting device (choke)

5

.
Only pull the choke lever half way out at outer temperatures over 5°C
(41°F). Pull the choke lever all the way out at outer temperatures below
5°C.

5 Do not accelerate; operate starter button

6

.

6 The oil pressure warning lamp

4

should go out as soon as the engine is

running.

7 Push the choke lever back in after a short time (max. 1 km, 0,6 mile).
8 Take the motorcycle off of the main stand or side stand.



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

!

–IFTHE OIL PRESSURE WARNING LAMP DOES NOT GO OUT AS SOON AS THE ENGINE IS

RUNNING

, IMMEDIATELY SWITCH OFF THE ENGINE. IFTHE ENGINE IS NOT SWITCHED

OFF

, ENGINE DAMAGE WILL OCCUR WITHIN A SHORT PERIOD OF TIME. CHECK THE

ENGINE OIL LEVEL OR CONTACT A KTM WORKSHOP

.

–M

AXIMUM 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 LET THE ENGINE WARM UP

BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM

.

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE
STARTER TIP SWITCH:
– the transmission is switched to idle
– Check if the emergency OFF switch is on
– Check if the ignition is on
– the headlight is on (Light switch in position).

– If this is not the case, the battery is discharged
– If the lights are on, proceed as described in the „Trouble-shooting“

section or contact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE
THE STARTER TIP SWITCH:
– Check if the fuel tap is open
– Check if the choke lever has been operated
– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank
– if sufficient fuel is in the tank, proceed as described in the „Trouble-

shooting“ 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 when the engine is warm or hot

1 Switch on emergency OFF switch 1.
2 Switch on ignition (turn ignition key

2

into position ).

3 Switch transmission to idle (green indicator lamp N

3

lights up).

4 Do not accelerate; operate starter button

6

.

5 The oil pressure warning lamp 4 should go out as soon as the engine is

running.

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

1

2

3

6

4

5