User manual KTM 640 LC4 ADVENTURE - 2003

640 LC4 ADVENTURE BEDIENUNGSANLEITUNG OWNER'S MANUAL MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art.Nr. 3.210.57 9/2002 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: 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 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 The 640 LC4 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 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 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 .........................................................6 Choke lever .................................................................6 Ignition lock with 3 switch positions.............................6 Multi-functional digital speedometer ..........................7 Setting options in the display .......................................8 Indicator lamps ............................................................9 Tachometer .................................................................9 Combination switch ...................................................10 Starter tip switch, emergency OFF switch, light switch10 Filler cap ....................................................................10 Fuel taps ....................................................................10 Shift lever ..................................................................11 Kickstarter..................................................................11 Foot brake pedal ........................................................11 Compression damping of fork ....................................12 Rebound damping of fork ..........................................12 Compression damping of shock absorber ...................12 Rebound damping of shock absorber .........................12 Baggage carrier ..........................................................12 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE14 Instructions for initial operation..................................14 Running in .................................................................14 DRIVING INSTRUCTIONS...................................................15 Check the following before each start ........................15 Starting when the engine is cold ................................16 Starting when the engine is waorm or hot .................16 What to do when the engine is flooded .....................16 Kickstart instructions ..................................................17 Starting off ................................................................17 Shifting, Riding ..........................................................17 Braking ......................................................................17 Stopping and parking.................................................18 Refueling ...................................................................18 PERIODIC MAINTENANCE-SCHEDULE ..............................20 MAINTENANCE WORK ON CHASSIS AND ENGINE...........22 Tool set......................................................................22 Removing the seat .....................................................22 Checking and adjusting steering head bearing ...........23 Bleeder screws front fork ...........................................23 Cleaning the dust sleeves of the telescopic fork..........23 Changing the spring preload of the shock absorber ...24 Checking rubber ring on the WP rear shock ansorber 24 Lubricate shock absorber linkage ...............................24 Checking chain tension ..............................................25 Correct chain tension .................................................25 Page Chain maintenance ....................................................26 Chain wear ................................................................26 General information 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 pedal ..29 Check the 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 ................30 Checking the shock absorbtion rubbers in the rear hub...........31 Tires, air pressure .......................................................31 Checking spoke tension .............................................32 Socket for electric accessories.....................................32 Battery .......................................................................33 Charging the battery..................................................33 Fuses .........................................................................34 Removing and mounting the headlight mask .............34 Replacing the headlight bulb......................................34 Exchanging the brake light and tail light blub.............35 Removing the tank ....................................................35 Cooling system ..........................................................36 Checking the cooling liquid level ................................36 Cleaning the air filter .................................................37 Adjusting the throttle cable ........................................38 Checking the oil level of the hydraulic clutch..............38 Changing the orginal position of the clutch lever .......38 Adjusting the choke cable play...................................39 Checking the adjustment of the hand decompression cable...39 Adjusting idling speed ................................................39 Draining of float chamber of the carburetor ...............40 Engine oil ...................................................................40 Checking the engine oil level .....................................40 Oil circuit ...................................................................41 Oil and fine screen filter change, bleeding of the oil system ....41 Changing oil filter .....................................................42 TROUBLE SHOOTING ........................................................43 CLEANING..........................................................................46 CONSERVATION FOR WINTER OPERATION.....................46 STORAGE ...........................................................................46 Re-initation after time of storage ...............................46 TECHNICAL SPECIFICATIONS - ENGINE ..........................48 TECHNICAL SPECIFICATIONS - CHASSIS .........................50 HEAD WORD INDEX ..........................................................52 WIRING DIAGRAM................................................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. Engine number, engine type 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 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). 1 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 ENGLISH 5 Hand brake lever The hand brake lever 1 is mounted on the handlebar on the right and actuates the front wheel brake.The adjusting screw B is used to change the original position of the hand brake lever (see maintenance work on chassis and engine). 1 B Choke lever If the choke lever 2 is pulled backwards, a bore 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. If the choke lever is pushed forward up to the stop, the bore will be closed again. In this position the choke cable must have a play of approx. 2 mm. ENGLISH 6 2 Ignition lock with 3 switch positions Switch positions of ignition lock 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 . 1 2 3 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. TEST TEST When you switch on the ignition, all of the display elements will light up for 1 second for the function test. WS 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 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 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 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 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 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. ENGLISH 7 Display 1 10 sec 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. 1 2 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). ENGLISH 8 2 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 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 at least 35 kilometers. After refueling, it will take approx. 3 minutes for TRIP F to automatically reset to 0 and return to the previous display mode. NOTE: To use up the reserve fuel in the tank, move the fuel cock to the RES position by hand. Cooling liquid temperature display 1 110°C (230°F) 100°C (212°F) 90°C (194°F) 80°C (176°F) 70°C (158°F) 60°C (140°F) 50°C (122°F) 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. 50°C. Each additional bar represents 10°C more. When the upper bar lights up, 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 (ALSO SEE PAGE 36): ­ 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 2 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. 110°C. 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). This warning light has no function. This indicator lamp has no function. Tachometer The tachometer 3 shows the engine speed in revolutions per minute (rpm). Do not push the engine into the red zone, which begins at 8500 rpm. 3 ENGLISH 9 4 Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch 2 returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button 3. The light signal (high beam) is actuated with button 4. 1 ENGLISH 10 1 2 3 Starter tip switch, emergency OFF tip switch, light switch Use the starter tip switch 5 to operate the electric starter. The light switch has 3 positions: 6 = Light off = Parking light on = Headlight on 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). 5 Filler cap To open: Turn the filler cap 7 anti-counterclockwise. To close: Screw on the filler cap clockwise. 7 Fuel taps The motorcycle is equipped with a fuel taps and 2 auxiliary fuel cocks. A fuel pump pumps the fuel from the tank to the carburetor. The auxiliary fuel cocks on the inside of the tank are connect the two tank chambers via a line. They must always be open. Open position: turn the knob to the limit in a counter-clockwise direction. NOTE: Only close the two auxiliary fuel cocks when you remove the fuel tank (see chapter on removing the tank). A Fuel tap A on the left side of the tank has 3 positions. OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel can flow to fuel pump. In this position the tank empties down to the fuel reserve of approx. 3,5 liters (0,9 US gallone). RES The reserve, approximately 3,5 liters (0,9 US gallone), cannot be tapped until the twist grip is turned to the RES position. Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time, too. NOTE: The fuel tap must be open during operation. The fuel tap must be closed for parking. OFF RES FUEL ON RES FUEL RES RES FUEL 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. 2,3,4,5 N 1 Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). ENGLISH O FF O FF O FF NO NO NO 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. BASIC SETTING ­ turn rotary knob clockwise as far as it will go ­ turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork WP 1418X728 . . . . . . . .14 clicks A 1 Rebound damping of fork ENGLISH 12 2 The rebound damping is to be set at the upper end of the fork tubes. It only regulates the degree of damping during rebounding. By using the knob 2 (REB), 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. BASIC SETTING ­ turn rotary knob clockwise as far as it will go ­ turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork WP 1418X728 . . . . . . . .14 clicks Compression damping of shock absorber With the knob 3 the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during compression. BASIC SETTING WP 0118X726 . . . . . . . .position 6 3 Rebound damping of shock absorber With the setting wheel 4 the degree of damping of the rebound can be adjusted to 11 positions. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding. BASIC SETTING: WP 0118X726 . . . . . . . .position 7 4 Baggage carrier The baggage carrier may be loaded with up to 10 kg. The two lateral hoops serve as handles for the passenger 13 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 the entire manual carefully before your first drive. ­ Enter the chassis, engine and key numbers on page 1. ­ Familiarize yourself with the operating elements. ­ Adjust the foot brake pedal to the most comfortable positions for you. ­ Make the basic settings on the multi-functional digital speedometer. ­ Get used to handling the motorcycle on an empty car park, 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 ability and experience. ­ Hold the handlebar with both hands and leave your feet on the foot rests while driving. ­ Remove your foot from the foot brake pedal when you are not braking. If the foot brake pedal is not released the brake pads rub continuously and the braking system is overheated. ­ You may only be accompanied by a passenger if your motorcycle is fitted and registered for such purposes. The passenger must hold tight to the brackets or hold on to the driver during the drive, with his feet on the passenger foot rests. ­ 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. ­ New tires have a smooth surface and must be run in. For this purpose, carefully ride the motorcycle at moderate speed, tilting the vehicle at different angles so that the surface is evenly roughened. Tires will not display their full grip characteristics before they are properly run in. ­ 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 and passenger with protective clothing and helmet. ­ Pay attention to running in instructions. 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 COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING. ALWAYS TURN ON THE LIGHT MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL. 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 VEHICLE'S DRIVING PROPERTIES. THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED 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. ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS. DRIVE CAREFULLY ON UNKNOWN ROADS REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, YOU WILL BE PRACTICALLY BLIND. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING. ­ ­ ­ ENGLISH 14 ­ ­ ­ ­ ­ ­ Running in 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 100 kilometers. 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 4800 rpm. Do not accelerate the engine up to the red mark on the tachometer (8500 r.p.m.) during a running-in period of 1000 km. 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. DRIVING INSTRUCTIONS Check the following before each start When you start off, the motorcycle must be in a perfect technical 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 THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 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. 3 CHAIN A loose chain can fall off; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear to the chain and rear sprockets. 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 reduce 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 garage, as complete failure of the braking system can be expected. Also check the state of the brake hoses and the thickness of the brake linings. Check free travel at hand brake lever and foot brake pedal. WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS "SPONGY" (TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON'T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. 6 CABLES Check correct setting and easy running of all control cables. 7 COOLING LIQUID Check the level of cooling liquid when the engine is cold. 8 ELECTRICAL SYSTEM Check headlight, parking light, tail light, brake light, flashers, indicator lamps and horn for faultless operation. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened. 15 ENGLISH Starting when the engine is cold 1 2 3 4 5 6 7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the choke lever 3. Operate the starter tip switch 4 without accelerating. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Swing up the centerstand 9 Switch on the light before setting off. WARNING 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. DO ENGLISH 16 5 ! ­ MAXIMUM ­ DON'T CAUTION 5 SECONDS. PERIOD FOR CONTINUOUS STARTING: SECONDS BEFORE TRYING AGAIN. ! WAIT AT LEAST 5 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 KEEP IN MIND THAT THE ENGINE SHOULD BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M. 1 2 IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: ­ the transmission is switched to idle ­ Check if the emergency OFF switch is on ­ Check if the ignition is on ­ the headlight is on. ­ If this is not the case, the battery is 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 ,,Troubleshooting" section or contact a KTM dealer. NOTE: THIS MOTORCYCLE IS EQUIPPED WITH A SAFETY STARTER SYSTEM. THE ENGINE CAN ONLY BE STARTED WHEN THE TRANSMISSION IS SWITCHED TO IDLE OR THE CLUTCH LEVER IS PULLED, RESPECTIVELY. 4 THE ELECTRIC STARTER DOESN'T CRANK THE ENGINE WHEN THE STARTER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELECTRIC CURRENT IS AVAILABLE: ­ Pull the hand decompression lever 5, start and release the lever. 3 Starting when the engine is warm or hot 1 2 3 4 5 6 7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the starter switch 4 without accelerating. Swing up the centerstand Switch on the light before setting off. What to do when the engine is ,,flooded" The throttle must be fully opened when starting. If necessary change spark plug. Starting the engine with the kickstarter Be sure to kick up the side or center stand before you start the engine to avoid any damage.Start as described above, then push the kickstarter hard all the way. WARNING ­ IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK THE KICKSTARTER. ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED THROTTLE GRIP INCREASE THE KICKBACK HAZARD. ! ­ 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 GIVING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN. SHIFT TO THE NEXT HIGHER GEAR BY 8500 RPM AT THE LATEST. NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL. IF THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE YOU ARE DRIVING, THIS INDICATES COOLING SYSTEM TROUBLE. IMMEDIATELY STOP AND TURN OFF THE ENGINE. DRIVING WITH THE WARNING LAMP ON WILL CAUSE ENGINE DAMAGE. ­ PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY, SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE. CAUTION SCALDING HAZARD! - AND CHECK THE COOLING LIQUID LEVEL. ­ DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. HOWEVER, CALL ON ONE OF KTM'S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED. IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT THE ENGINE FASTENING SCREWS ARE TIGHT. IN THE EVENT THAT, WHILE RIDING YOUR MOTORCYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. 17 Braking 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 OFF, CHECK THAT THE CENTER STAND HAS BEEN SWUNG RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL. 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 feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. 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. WARNING ­ DELAYED ­ ­ BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE. IN THIS CASE, REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY. DELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY ROADS. IN THIS CASE, REPEATEDLY APPLY THE BRAKES TO REMOVE THE DIRT. WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL. DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS. Shifting/Riding You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, road gradient, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever and shift to the next higher gear. Let clutch lever go again and 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 turning the throttle grip all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Never open the throttle wider than the engine can handle. Excessive turning of the throttle grip will increase full 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. WARNING ­ AVOID ­ ­ ­ ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY ROADS. OTHERWISE, THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL. NEVER TURN THE IGNITION KEY TO POSITION OR WHILE THE MOTORCYCLE IS MOVING. DO NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE. AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN. ­ ENGLISH Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Close fuel tap. Park on solid ground and lock the vehicle. WARNING ­ MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, 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. NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS. ­ ! ­ PARK CAUTION ! ­ ­ ­ YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD GROUND, LEVEL SURFACE) AND CAN'T TIP OVER. DO NOT LEAVE THE PARKING LIGHT ON FOR MORE THAN THREE HOURS WITH THE ENGINE OFF. OTHERWISE YOU WILL NOT BE ABLE TO START THE ENGINE WITH THE ELECTRIC STARTER. THE FUEL TAPS MUST ALWAYS BE CLOSED WHEN PARKING THE MOTORCYCLE. OTHERWISE THE CARBURETOR CAN OVERFLOW AND FUEL COULD FLOW INTO THE ENGINE. ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS. ENGLISH 18 35 mm NOTE REGARDING THE CENTER STAND: We advice the following procedure to place the motorcycle on the center stand as effortlessly as possible: a) press main stand to ground using foot, b) swing out kickstarter and pull motocycle backwards at an angle as illustrated (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely. Refueling The LC4 engine needs premium gasoline with an octane number of 95 or higher. CAUTION ! ­ USE UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. ­ BE CAREFUL NOT TO LET FUEL DRIP ON THE PAINTED PARTS, WIPE UP ANY SPILLS IMMEDIATELY. THE FUEL WILL DISCOLOR THE CLEAR COAT AND MAKE IT TURN YELLOW. ! Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). 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. 19 ENGLISH