KTM Supermoto 950 2006 Owner's manual

950 SUPERMOTO

ART. NR. 3.211.82EN

OWNER’S MANUAL 2006

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:

– IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR

BODY AND YOUR LIFE.

– IGNORING THESE INSTRUCTIONS COULD CAUSE DAM-

AGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

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. © 2005 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

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

IMPORTANT »

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.

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

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »

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

The 950 Supermoto is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain.

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 chart" must be carried out by an authorized KTM workshop and confirmed in the service manual, otherwise your warranty will become 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 the race course, can cause above average wear to components such as 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.

INDEX »

IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IMPORTANT LIMITED WARRANTY AND LIMITED

GUARANTEE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . .3

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

Chassis number, Type label . . . . . . . . . . . . . . . . . . . . . . . . .6

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

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

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

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

Multi-functional digital speedometer . . . . . . . . . . . . . . . . . .8

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Setting options in the display . . . . . . . . . . . . . . . . . . . . . .10

Cooling liquid temperature display . . . . . . . . . . . . . . . . . .12

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

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

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

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

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

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

Baggage carrier, grips . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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

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

Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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

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

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

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

Compression damping of fork . . . . . . . . . . . . . . . . . . . . . .18

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

Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . . . .18

Damping action during compression of shock absorber . . . .19

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

GENERAL TIPS AND WARNINGS FOR STARTING

THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

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

Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . . . . .20

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

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

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

Starting when the engine is cold . . . . . . . . . . . . . . . . . . . .24

Starting when the engine is warm or hot . . . . . . . . . . . . . .25

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

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

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

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

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

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .29

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .33

Adjusting the fork and shock absorber . . . . . . . . . . . . . . .34

Adjusting compression damping of fork . . . . . . . . . . . . . . .34

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

Adjusting the spring preload on the fork . . . . . . . . . . . . . . .35

Compression damping of shock absorber . . . . . . . . . . . . . .36

Rebound damping of shock absorber . . . . . . . . . . . . . . . . .37

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

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

Checking the front brake fluid level . . . . . . . . . . . . . . . . .42

Refilling front brake fluid . . . . . . . . . . . . . . . . . . . . . . . . .42

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

Changing the basic position of the foot brake lever . . . . . . .44

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

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . . .44

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .45

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

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

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Fuses for individual power consumers . . . . . . . . . . . . . . . .54

Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .55

Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .56

Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .56

Replacing the brake light and taillight bulbs . . . . . . . . . . .57

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

Checking the cooling liquid level in the compensating tank .59

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

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . .60

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

Checking the oil level of the hydraulic clutch . . . . . . . . . . .62

Checking and adjusting the throttle cable play . . . . . . . . . .63

Checking and adjusting the choke cable play . . . . . . . . . . .63

Adjusting the engine idle speed . . . . . . . . . . . . . . . . . . . .63

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

Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .64

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

Changing the engine oil and the oil filter, cleaning the oil

screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .73

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .75

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .79

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

CONSUMER INFORMATION FOR USA ONLY . . . . . . . . . . . . .83

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

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.

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 right side of the handlebar.The basic position of the handbrake lever can be changed in 5 steps (see Maintenance work on chassis and engine).

OPERATION INSTRUMENTS »

Multi-functional digital speedometer

The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display. Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button.

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

Display

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

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

OPERATION INSTRUMENTS »

TEST

31 2

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 mode (fuel) displays the speed, the temperature of the cooling liquid and the distance traveled since reaching the low-fuel mark (the low-fuel indicator lamp lights up). To return to the CLOCK mode, press the MODE button.

OPERATION INSTRUMENTS »

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

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 long-distance 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.

SET 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 [2].

OPERATION INSTRUMENTS »

10 sec

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 [2].

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 light up. You will still have enough reserve fuel for at least 30 kilometers. After refueling, it will take approx. 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode.

NOTE: Press the SET key for 2 seconds to immediately turn off the fuel warning lamp.

OPERATION INSTRUMENTS »

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.

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

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 light up when the fuel level reaches 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.

OPERATION INSTRUMENTS »

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)

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].

OPERATION INSTRUMENTS »

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 pump stops running when the engine is switched off and fuel cannot flow to the carburetors so the fuel taps do not need to be closed when the motorcycle is switched off.

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 [3] 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.

Baggage carrier, grips

The baggage carrier [1] can carry a load of up to 8 kg. The passenger can hold on to the grips [2] during the ride.

To mount the seat, attach the seat to the oval head screw [4]

, lower the seat in the back while sliding it towards the front. Both noses [5] should fit into the frame. Insert the catch bolts [6] 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 »

Tool set

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

Helmet lock

The steel rope [2] in the tool bag can be used to secure a helmet. To secure, remove the seat, run the rope through the helmet, attach both ends to the hook [3] and mount the seat.

THE HELMET LOCK IS PROVIDED TO SECURE THE HELMET TO THE MOTORCYCLE WHEN PARKED. DO NOT ATTACH THE HELMET OR OTHER OBJECTS TO THE STEEL ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE.

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 »

2,3,4,5,6

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

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.“

Spring preload of the fork

The fork's preload can be adjusted by means of the adjusting screws [3]. More information is provided in the chapter "Adjusting the fork and shock absorber.“

OPERATION INSTRUMENTS »

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 [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 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 [3] is located on the bottom of the shock absorber. More information is provided in the chapter "Adjusting the fork and shock absorber.“

OPERATION INSTRUMENTS »

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 hand brake lever and foot brake

lever to your most comfortable position.

– This motorcycle is equipped with 2 cat-

alytic 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 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 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 (125 miles) 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 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). Do not exceed the maximum speeds listed in the table during this time.

– WEAR SUITABLE CLOTHING WHEN DRIV-

ING 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.

GEAR MAXIMUM SPEED

1st 55 km/h (35 mile/h) 2nd 75 km/h (45 mile/h) 3rd 100 km/h (60 mile/h) 4th 120 km/h (75 mile/h) 5th 145 km/h (90 mile/h) 6th 170 km/h (105 mile/h)

GENERAL TIPS AND WARNINGS FOR STARTING 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.

– THE TIRES MUST BE DESIGNED FOR A

SPEED OF OVER 240 KPH (SPEED SYMBOL ZR) AND MUST BE RELEASED BY KTM.

– 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 SEN-

SITIVE 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 – 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 OPER-

ATOR WILL BE BLINDED.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT

SUPERVISION IF THE ENGINE IS RUNNING.

Accessories and payload

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

– 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

– THE BAGGAGE CARRIER CAN CARRY A LOAD

OF UP TO 8 KG (17.7 LBS).

– IF YOU HAVE CASES MOUNTED, DO NOT

EXCEED THE MANUFACTURER'S RECOMMENDED MAXIMUM PAYLOAD.

– FASTEN THE BAGGAGE CLOSE TO THE CEN-

TER OF THE MOTORCYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR WHEELS AND ON THE LEFT AND RIGHT.

– BAGGAGE MUST BE SECURELY AND ADE-

QUATELY FASTENEND; LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.

– A HIGH PAYLOAD WILL CHANGE THE MOTOR-

CYCLE'S HANDLING AND CONSIDERABLY

INCREASE THE BRAKING DISTANCE; ADAPT YOUR DRIVING SPEED ACCORDINGLY.

– NEVER EXCEED THE MAXIMUM PERMISSI-

BLE 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

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.

DRIVING INSTRUCTIONS »

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 (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 (205 kg, 452 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. 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 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) [4].

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 [5]. 6 The oil pressure warning lamp [6] should go out as soon as the engine is running. 7 Take the motorcycle off of the side stand. 8 Push the choke lever back in after a short time (max. 1 km, 0,6 mile).

– 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.

– NEVER OPERATE THE MOTORCYCLE WITH A RUN-DOWN BATTERY OR WITHOUT THE BATTERY.

THIS CAN DAMAGE THE ELECTRONIC COMPONENTS OR SAFETY EQUIPMENT IN EITHER CASE-

AND THE MOTORCYCLE WILL NO LONGER BE ROADWORTHY.

– IF THE OIL PRESSURE WARNING LAMP DOES NOT GO OUT AS SOON AS THE ENGINE IS RUN-

NING, IMMEDIATELY SWITCH OFF THE ENGINE. IF THE 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.

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

BEFORE TRYING AGAIN.

– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN COLD.

BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN

CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM

DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM.

– RELEASE THE CHOKE LEVER AFTER A MAXIMUM OF 1 KILOMETER (0,6 MILE) OTHERWISE

THE CATALYTIC CONVERTERS WILL BE DESTROYED.

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 (the light is switched

off when actuating the starter button) –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 taps are 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. 2 Switch on ignition (turn ignition key into

position ).

3 Switch transmission to idle (green indi-

cator lamp N lights up). 4 Do not accelerate; operate starter button. 5 The oil pressure warning lamp should go

out as soon as the engine is running. 6 Take the motorcycle off of the side stand.

Starting off

Pull the clutch lever and engage 1st gear. Slowly release the clutch lever while you open the throttle.

DO NOT ATTACH A HELMET OR OTHER OBJECTS TO THE HELMET LOCK ROPE WHILE DRIVING. YOU CAN EASILY LOSE CONTROL OF THE MOTORCYCLE.

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 the throttle while pulling the clutch lever, engage the next gear, release the clutch lever and carefully open the throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm.

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.

– AVOID ABRUPT LOAD CHANGES WHILE RID-

ING 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 SETTINGS OF

THE MULTI-FUNCTIONAL DIGITAL SPEEDOMETER WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE.

DRIVING INSTRUCTIONS »

– THE PASSENGER MUST HOLD ON TO THE

DRIVER OR THE GRAB HANDLE ON THE BAGGAGE CARRIER DURING THE RIDE AND KEEP HIS FEET ON THE PASSENGER FOOTRESTS.

– REGULARLY MAKE SURE THAT THE BAG-

GAGE AND CASES ARE TIGHTLY FASTENED.

– 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 4TH BAR ON THE TEMPERATURE INDICATOR LIGHTS UP.

– IF THE RED OIL PRESSURE WARNING LAMP

LIGHTS UP WHILE DRIVING, THE OIL PRESSURE IS TOO LOW TO ADEQUATELY LUBRICATE THE ENGINE. STOP IMMEDIATELY AND SWITCH OFF THE ENGINE. IF YOU CONTINUE TO DRIVE, ENGINE DAMAGE WILL OCCUR WITHIN A SHORT PERIOD OF TIME. CHECK THE ENGINE OIL LEVEL OR CONTACT AN AUTHORIZED KTM WORKSHOP.

– NEVER HAVE THE THROTTLE WIDE OPEN

WHEN CHANGING DOWN TO A LOWER GEAR.

THE ENGINE WILL OVERSPEED, DAMAG-

ING THE VALVES. IN ADDITION, THE REAR

WHEEL BLOCKS SO THAT THE MOTORCY-

CLE 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.

– STOP IMMEDIATELY IF A PERCEPTIBLE

POWER LOSS OCCURS WHILE DRIVING DUE

TO A DEFECTIVE IGNITION CAUSED BY A

CYLINDER MISFIRING OR BREAKING DOWN.

IF THE UNBURNED FUEL/AIR MIXTURE

REACHES THE CATALYTIC CONVERTER, IT

WILL IGNITE AND THE RESULTING HEAT

WILL DESTROY THE CATALYTIC CONVERTER

AND THE ADJOINING COMPONENTS.

– THE RED COOLANT WARNING LAMP LIGHTS

UP WHEN THE COOLANT TEMPERATURE

HAS REACHED 120°C (248°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

INSUFFICIENT – 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.

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