User manual KTM 625 LC4 SXC - 2003

625 SXC BEDIENUNGSANLEITUNG OWNER'S MANUAL MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art.Nr. 3.210.53 8/2002 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS, MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS. ANNOUNCEMENT. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION. ENGLISH 1 WARNING Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it. We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer. For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer. Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others. We wish you a lot of fun when driving ! ENGLISH 2 KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA Attachments: Spare parts manual chassis & engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL. © by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty. The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule. The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle. The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. ENGLISH 3 The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components. Index Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number ................................................................5 Engine number, engine type.............................................5 OPERATION INSTRUMENTS ...............................................5 Clutch lever ......................................................................5 Hand decompression lever................................................5 Hand brake lever ..............................................................5 Indicator lamps.................................................................6 Electronic speedometer.....................................................6 Tripmaster switch .............................................................7 Overview of tripmaster functions ...................................10 Ignition lock ...................................................................11 Combination switch........................................................11 Flasher switch.................................................................11 Emergency OFF button ..................................................11 Filler cap.........................................................................11 Fuel tap ..........................................................................12 Choke ............................................................................12 Hot start device ..............................................................12 Shift lever .......................................................................12 Kickstarter ......................................................................13 Foot brake pedal ............................................................13 Handlebar lock ...............................................................13 Compression damping of fork ........................................14 Rebound damping of fork ..............................................14 Compression damping of shock absorber .......................14 Rebound damping of shock absorber .............................14 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE...................................................................16 DRIVING INSTRUCTIONS ..................................................17 PERIODIC MAINTENANCE-SCHEDULE ..............................20 MAINTENANCE WORK ON CHASSIS AND ENGINE ..........22 Removal of seat..............................................................22 Tool set ..........................................................................22 Check and adjust steering head bearing .........................23 Breather plugs front fork ................................................23 Cleaning the dust sleeves of the telescopic fork ..............23 How to change the handlebar position ...........................24 Changing the spring preloading of the shock absorber ...24 Checking rubber ring on the WP rear shock absorber .....25 Lubricate rear suspension linkage ...................................25 Checking chain tension...................................................25 Correct chain tension......................................................25 Chain maintenance.........................................................26 Chain wear.....................................................................26 General informations about KTM disc brakes..................27 Adjusting of free travel at the hand brake lever ..............28 Checking brake fluid level - front brake ..........................28 Refilling the front brake fluid reservoir............................28 Check the front brake pads ............................................28 Replacing front brake pads .............................................29 Check the rear brake fluid level ......................................29 Refilling the rear brake fluid reservoir .............................29 Page Changing the basic position of the brake pedal ..............30 Checking the rear brake pads .........................................30 Replacing the rear brake pads.........................................30 Dismounting and mounting the front wheel ...................31 Dismounting and mounting the rear wheel.....................31 Tires, air pressure............................................................32 Checking spoke tension..................................................32 Battery for digital speedometer.......................................32 Kilometers or miles .........................................................32 Check/set distance of the magnetic sensor .....................33 Setting the clock.............................................................33 Activating/deactivating the display modes......................33 Battery ...........................................................................34 Charging the battery ......................................................34 Fuses ..............................................................................35 Replacing headlight lamp/parking light lamp..................35 Exchanging the brake light and tail light bulb .................36 Cooling system...............................................................36 Checking the coolant level..............................................37 Cleaning air filter ............................................................37 Exhaust system...............................................................38 Cleaning the spark arrester (USA)...................................38 Adjusting the throttle cable ............................................39 Checking the adjustment of the hand decompression cable ..39 Checking the oil level of the hydraulic clutch ..................40 Bleeding of the hydraulic clutch......................................40 Draining the float chamber of the carburetor..................40 Carburetor ­ Adjust idling (Keihin FCR-MX41) ...............41 Adjusting the mixture control screw ...............................41 Checking the float level (Keihin FCR-MX41)...................41 Carburetor ­ Adjust idling (Mikuni BST40)......................42 Checking the float level (Mikuni BST40) .........................42 Engine oil .......................................................................43 Checking the engine oil level ..........................................43 Oil circuit........................................................................43 Changing the engine oil .................................................44 Changing and bleeding the microfilter............................44 Changing oil filter...........................................................45 TROUBLE SHOOTING ........................................................46 CLEANING..........................................................................49 CONSERVATION FOR WINTER OPERATION ....................49 STORAGE ...........................................................................49 Re-initation after time of storage....................................49 TECHNICAL SPECIFICATIONS - ENGINE ...........................50 TECHNICAL SPECIFICATIONS - CHASSIS...........................52 CONSUMER INFORMATION FOR USA ONLY...................54 HEAD WORD INDEX ..........................................................57 WIRING DIAGRAMME ..........................................APPENDIX ENGLISH 4 SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. Write this number into the relevant area on page 1. OPERATION INSTRUMENTS 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). A Hand decompression lever The hand decompression lever 2 is only used in two special cases: a) When the engine stalled. It is possible that the starter motor is not able to crank the engine on the next attempt. This is due to the fact that the automatic decompressor doesn't work properly. If this happens, pull the manual decompression lever and start again. Afterwards normal starting will be possible. b) When you want to push the motorcycle. While pushing, pull the hand decompression lever to make it easier to get the engine going. 2 Hand brake lever The hand brake lever is mounted on the right side of the handle bar and actuates the front wheel brake. ENGLISH 5 Engine number, engine type Indicator lamps 3 The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. The orange indicator lamp 3 will light when the ignition is switched on. 1 2 Indicator lamp (USA) ENGLISH 6 4 The orange indicator lamp 4 will light when the ignition is switched on. Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move. The engine must be started in order for the speedometer to be supplied with electricity from the generator. The display is not activated until the front wheel has made 1 revolution (impulse for speedometer). TEST All of the display elements will light up for 1 second for the function test. WS (wheel size) The display will change and briefly show the diameter of the front wheel in millimeters. If the front wheel does not turn, the display will automatically change to the SPEED/H mode. If the front wheel turns, the display will automatically change to the SPEED /ODO mode. SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. SPEED/ODO display mode The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode. The information will disappear in the display when the front wheel stops turning for 1 minute. + ­ The switch has 3 buttons: MODE, + (plus) and ­ (minus). The tripmaster switch is mounted on the outer left of the handlebar on the USA models. The switch is located to the left of the speedometer on European models but can also be mounted on the outer left of the handlebar with a retaining clamp (ET.NO. 583.14.069.350). WARNING NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT. MODE MODE DO ­ + Electronic speedometer functions provided by the Tripmaster switch The display modes on the electronic speedometer will change in the following order. If not, please read the chapter "ACTIVATING AND DEACTIVATING THE DISPLAY MODE." SPEED/ODO display mode SPEED displays the speed in KPH or MPH. The displayed figure cannot be cleared. ODO displays the kilometers or miles traveled. The displayed figure cannot be cleared. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode SPEED/MAX display mode MAX displays the maximum speed. It is always active. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0 SPEED/LAP display mode LAP displays the stopped lap time in hours, minutes and seconds. Starts and stops the stop watch. The lap time is not reset to 0. Stops the running stop watch, stores the lap time and restarts the stop watch. The time is reset to 0. A total of 10 lap times can be stored and read in the SPEED/LAP display mode. To clear all of the stored lap times, hold the MODE button for 3 seconds in the SPEED/LAP mode. press the MODE BUTTON to change to the next mode If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all stored lap times to 0 + BUTTON ­ BUTTON ENGLISH 7 Tripmaster switch LAP/LAP display mode The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the stored lap times. + BUTTON changes to the next lap time. ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode SPEED/CLK (clock) display mode CLK will display time in hours, minutes and seconds. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK) ENGLISH 8 SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the SETUP mode (see REVEALING/CONCEALING functions). SPEED/TRP1 (trip 1) display mode The TRP1 trip meter is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops. TRP1 is linked to AVS1 and STP1. The calculation of these figures is activated by the first impulse received from the wheel sensor (when the front wheel starts to turn) and stops 3 seconds after the last impulse is received (when the front wheel has stopped). The TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing 999.9. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to automatically reset the TRP1, AVS1 and STP1 figures to 0. SPEED/AVS1 (average speed 1) display mode AVS1 is always active and shows the average speed based on the TRP1 and STP1 figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0. SPEED/STP1 (stop 1) display mode STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0. + BUTTON increases the TRP2 figure ­ BUTTON decreases the TRP2 figure press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset TRP2 to 0 SPEED/AVS2 (average speed 2) display mode AVS2 shows the average speed based on the TRP2 and STP2 figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 was not stopped after the trip. + BUTTON no function ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode SPEED/STP2 (stop 2) display mode STP2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing. Press the MODE button to change to the next mode. The STP2 display will blink in the other modes if STP2 continues to run in the background. To stop STP2, return to the SPEED/STP2 mode and press the + button. + BUTTON starts and stops the stop watch ­ BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset STP2 figures to 0 ENGLISH 9 SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and ­ buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received. Standing motorcycle Driving motorcycle OVERVIEW OF TRIPMASTER FUNCTIONS Display Press + Press ­ Press MODE next display mode next display mode next display mode Hold MODE for 3 sec no function resets MAX to 0 clears all LAP figures X SPEED / ODO X X X SPEED / MAX X SPEED / LAP no function no function starts / stops LAP figure LAP remains next figure no function no function no function no function no function stops LAP, stores LAP figure, resets LAP to 0 no function no function no function no function ENGLISH 10 X X X X X LAP / LAP SPEED / CLK SPEED / H X SPEED / TRP1 next display mode next display mode next display mode next display mode next display mode set clock menu display setup menu resets TRP1, STP1 and AVS1 to 0 resets TRP1, STP1 and AVS1 to 0 resets TRP1, STP1 and AVS1 to 0 resets TRP2 to 0 next display mode sets STP2 to 0 X X SPEED / AVS1 no function no function next display mode X X SPEED / STP1 no function no function next display mode X X X X SPEED / TRP2 X SPEED / AVS2 X SPEED / STP2 increases TRP2 figure no function starts / stops STP2 decreases TRP2 figure no function no function next display mode next display mode next display mode Ignition lock Switch positions of ignition lock 1: Ignition off, light off (engine can't be started) Ignition on, light off (engine can be started) Ignition on, light on (engine can be started) 1 Combination switch The light switch has 2 switch positions. A = Low beam light B = High beam light The red short circuit button 2 serves to switch off the engine. Leave the switch pressed, until the engine stops. With the button 3 the horn will sound. B A 11 Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Emergency OFF button The red emergency-OFF button 4 is arranged adjacent to the throttle grip. To turn off the engine, push the button until the engine comes to a standstill. 4 Pushing the black starter button 5 will actuate the E-starter. 5 Filler cap To open filler cap: Turn the filler cap counter-clockwise. To close filler cap: Screw on the filler cap clockwise. 6 Install tank breather hose 6 without kinks. ENGLISH 3 2 Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the rotating handle must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx. 2,5 liters. RES The reserve tank, approximately 2,5 liters, cannot be tapped until the rotating handle is turned to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too. OFF RES FUEL O FF ON RES FUEL O FF RES RES FUEL O FF 1 12 Choke (Keihin FCR - MX41) If you pull the choke button 2 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a ,,fat" fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. 2 3 2,3,4,5 N 1 NO NO NO Choke (Mikuni BST40) By pulling the choke control knob 1 downwards and turning it approx. 90°, a hole will be opened in the carburetor through which the engine can draw in additional fuel. The result is a ,,fat" fuel-air mixture of the type needed for cold starts. Turning back the choke control knob returns the knob to the starting position and closes the hole in the carburetor again. ENGLISH Hot start device (Keihin FCR - MX41) If you pull the hot start device 3 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a ,,lean" fuel-air mixture of the type needed for hot starts. To deactivate the hot start device, push the hot start button back into its basic position. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral position is located between first and second gear. Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. The foot brake pedal is located in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). 13 Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw. ! NEVER LEAVE THE KEY INSERTED IN THE LOCK. THE KEY COULD GET DAMAGED. CAUTION IF YOU ! TURN THE STEERING TO THE LEFT ENGLISH Foot brake pedal Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap A. By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression. STANDARD ADJUSTMENT: ­ turn adjusting screw clockwise as far as it will go ­ turn it back by as many clicks as are specified for the relevant type of fork WP 0518X729 ..................... 20 clicks A 1 Rebound damping of fork ENGLISH 14 2 2 Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the knob 2, the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding. STANDARD ADJUSTMENT: ­ turn adjusting screw clockwise as far as it will go ­ turn it back by as many clicks as are specified for the relevant type of fork WP 0518X729 ..................... 12 clicks Compression damping of shock absorber With the knob 3 the degree of damping of the compression can be adjusted. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during rebounding. STANDARD ADJUSTMENT: WP 0118X725 ................... position 3 3 Rebound damping of shock absorber With the setting wheel 4 the degree of damping of the rebound can be adjusted. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding. STANDARD ADJUSTMENT: WP 0118X725 ................... position 5 4 15 ENGLISH GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation ­ Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). ­ Read these operating instructions carefully before your first ride. ­ Enter the chassis, engine and key numbers on page 1. ­ Familiarize yourself with the operating elements. ­ Adjust the hand brake lever and foot brake lever to your most comfortable position. ­ Get used to handling the motorcycle on an empty parking lot or open space, before starting on a longer drive. Also try to drive as slowly as possible and in standing position, to improve your feeling for the vehicle. ­ Do not drive along off-road tracks which go beyond your abitily and experience. ­ Hold the handlebars with both hands and leave your feet on the foot rests while driving. ­ Remove your foot from the foot brake lever when you are not braking. If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated. ­ Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle. ­ Motorcycles are sensitive to alterations in the distribution of weight. If you are taking luggage with you, this should be secured as close as possible to the middle of the vehicle; distribute the weight evenly between the front and rear wheel. Never exceed the maximum permissible laden weight and the axle weights. The maximum permissible laden weight is made up of the following components: ­ Motorcycle ready for operation and tank full ­ Luggage ­ Driver with protective clothing and helmet. ­ Pay attention to running-in procedure. WARNING ­ WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING. DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL. ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES. THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE. OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE. CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS. DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS. RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, THE OPERATOR WILL BE BLINDED. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING. THESE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY NO ADDITIONAL PASSENGER ALLOWED! WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE. ­ ­ ­ ENGLISH 16 ­ ­ ­ ­ ­ ­ ­ ­ Running in the LC4 models Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding against one another for quite some time. Therefore, every engine needs to be broken in. For this reason, during its first 1000 kilometers (620 miles) the engine must not be revved up to its performance limits. The engine speed of 4800 r.p.m. must not be exceeded during the first 1000 kilometers (620 miles). During this break-in time, you should ride your motorcycle in different conditions (roads, easy off-road terrain). The following table shows you the maximum velocity values in the different gears at 4800 r.p.m. as based on the rear wheel transmission ratio of your motorcycle. ratio gear 625 SXC 16:40 Z 35 kmh 60 kmh 80 kmh 100 kmh 115 kmh 625 SXC 15:50 Z 30 kmh 45 kmh 60 kmh 75 kmh 90 kmh 1. G 2. G 3. G 4. G 5. G NOTE: DURING THE STAGE OF RUNNING THE ENGINE IN, THAT IS 1000 KM (620 MILES), THE ENGINE OIL USED SHOULD MINERAL OIL FORMULA. THIS ALSO APPLIES IF THE ENGINE REPAIRED. THE FIRST BE OF A HAS BEEN 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 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 3 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. 4 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. 5 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. 6 CABLES Check correct setting and smooth operation of all control cables. 7 COOLING FLUID Check the level of cooling fluid when the engine is cold. 8 ELECTRICAL SYSTEM Check correct operation of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened. 17 ENGLISH 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks. Starting when the engine is cold 1 2 3 4 5 6 Open the fuel tap 1 Switch on ignition (turn ignition key 2 into position Swing up the side stand or center stand Put the gear in neutral Operate the choke 5 Do not accelerate; operate starter button 3 WARNING ­ TO AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER. DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING. ) 1 ­ ! DON'T CAUTION ! RIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ENGLISH 18 3 5 Starting when the engine is warm or hot 1 2 3 4 5 6 Open the fuel tap 1 Switch on ignition (turn ignition key 2 into position ) Swing up the side stand or center stand Put the gear in neutral Push the hot start button 4 (Keihin carburetors only) Do not accelerate; operate starter button 3 2 What to do when the engine is ,,flooded" The throttle must be fully opened when starting. If necessary change sparkplug. Starting off Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time. WARNING BEFORE YOU START, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GET OUT OF CONTROL. Shifting/Riding You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in and shift to the next higher gear. Let clutch lever go again and open throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm. When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed will not decreases but the engine will use less fuel. Only give as much throttle as the engine can handle. Through quick and high reving of throttle, the fuel consumption increases. When shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throttle or shift down again. 4 Kickstart instructions Start as described above, then push the kickstarter hard ALL THE WAY. WARNING ­ WHEN STARTING THE ENGINE, MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY. YOU MIGHT SLIDE OFF THE KICKSTARTER, OR THE ENGINE MAY CAUSE THE KICKSTARTER TO RECOIL, THEREBY CAUSING INJURIES TO FOOT AND LEG. ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND, WHILE DOING SO, NEVER OPEN THE THROTTLE. KICKSTARTING WITH INSUFFICIENT MOMENTUM AND AN OPENED THROTTLE LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL. ­ WARNING ­ AVOID ­ ­ ­ ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE CONTROL OF YOUR MOTORCYCLE. WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE. 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. ! ­ CLOSE ­ CAUTION ! THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE. NEVER PARK YOUR MOTORCYCLE IN FIRE HAZARDOUS PLACES DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS. ! ­ HIGH CAUTION ! ­ ­ ­ ­ 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 TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM. NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL. LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO MOTOR DAMAGE. IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT. IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU NOISE, STOP NOTICE ANY UNUSUAL OPERATION-RELATED IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. NOTE REGARDING THE MAIN STAND: We advise the following procedure to place the motorcycle on the main stand as effortlessly as possible: a) press main stand to ground using foot. b) swing out kickstarter and pull at an angle toward the rear of motorcycle (see illustration). 19 Braking Close throttle and apply the hand and foot brakes at the same time. When driving on sandy, wet or slippery ground use mainly the rear wheel brake. Always brake with care, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. When driving down hill, use the braking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to brake so much and the brakes will not overheat. WARNING ­ WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BREAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL. IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS, HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN. RIDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN. DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS. Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher. ! USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. ! CAUTION WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR'S ADVICE IMMEDIATELY. ­ Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). ­ ­ Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition or pull the short circuit button when the engine is idling, until the engine stops. Turn the fuel tap to the OFF position, park on an area with firm ground, and lock the motorcycle. WARNING ­ ­ ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE. MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED. 35 mm ENGLISH