640 LC4 ENDURO 640 LC4 SUPERMOTO BEDIENUNGSANLEITUNG OWNER'S MANUAL MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art.Nr. 3.210.56 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 The 640 LC4 models are designed to withstand normal use on roads and easy terrain (unpaved roads). The 640 LC4 Supermoto models are not suitable for use off of paved roads. 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. 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 Multi-functional digital speedometer ................................6 Seeting options in the display ...........................................7 Indicator lamps.................................................................8 Choke lever ......................................................................8 Ignition lock .....................................................................8 Combination switch..........................................................9 Starter tip switch, emergency OFF switch, light switch .....9 Filler cap...........................................................................9 Fuel tap ..........................................................................10 Shift lever .......................................................................10 Kickstarter ......................................................................10 Foot brake pedal ............................................................10 Compression damping of fork ........................................11 Rebound damping of fork ..............................................11 Compression damping of shock absorber .......................11 Rebound damping of shock absorber .............................11 Holding bars...................................................................11 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE...................................................................12 Instructions for initial operation ......................................12 Running in the LC4 models ............................................12 DRIVING INSTRUCTIONS ..................................................13 Check the following before each start ............................13 Starting when the engine is cold.....................................14 Starting when the engine is warm or hot ........................14 What to do when the engine is ,,flooded"......................14 Kickstart instructions.......................................................15 Starting off .....................................................................15 Shifting, Riding...............................................................15 Braking...........................................................................15 Stopping and parkling ....................................................16 Fuel ................................................................................16 PERIODIC MAINTENANCE-SCHEDULE ..............................18 MAINTENANCE WORK ON CHASSIS AND ENGINE ..........20 Tool set ..........................................................................20 Removing the seat..........................................................20 Checking and adjusting steering head bearing................21 Breather plug front fork..................................................21 Cleaning the dust sleeves of the telescopic fork ..............21 Changing the spring preload of the shock absorber ........22 Lubricate shock absorber linkage ....................................22 Checking rubber ring on the rear shock absorber............22 Checking chain tension...................................................23 Correct chain tension......................................................23 Page Chain maintenance.........................................................24 Chain wear.....................................................................24 General information on KTM disc brakes ........................25 Adjisting of free travel at the hand brake lever ...............26 Checking of brake fluid level - front brake......................26 Refilling the front brake fluid reservoir............................26 Checking the front brake pads........................................26 Changing the basic position of the foot brake pedal .......27 Check the rear brake fluid level ......................................27 Refilling the rear brake fluid reservoir .............................27 Checking the rear brake pads .........................................27 Dismounting and mounting the front wheel (LC4) .........28 Dismounting and mounting the front wheel (LC4 Supermoto)............................................................28 Dismounting and mounting the rear wheel.....................29 Checking the shock absorbtion rubbers in the rear hub ..29 Tires, air pressure............................................................30 Checking spoke tension..................................................30 Changing the wheel size.................................................30 Battery ...........................................................................31 Charging the battery ......................................................31 Fuses ..............................................................................32 Exchanging the headlight lamp.......................................32 Replacing the parking light bulb .....................................32 Exchanging the brake light and tail light bulb .................33 Cooling system...............................................................33 Checking the cooling liquid level ....................................34 Cleaning the air filter ......................................................34 Adjusting the throttle cable ............................................35 Checking the oil level of the hydraulic clutch ..................35 Changing the orginal position of the clutch lever............35 Checking and adjusting the chocke cable play ................36 Checking the adjustment of the hand decompression cable ..36 Adjust idling speed .........................................................36 Draining the carburetor float chamber............................37 Engine oil .......................................................................37 Checking the engine oil level ..........................................37 Oil circuit........................................................................38 Oil and fine screen filter change, bleeding of the oil system ..38 Changing oil filter ..........................................................39 TROUBLE SHOOTING ........................................................40 CLEANING..........................................................................43 CONSERVATION FOR WINTER OPERATION ....................43 STORAGE ...........................................................................43 Re-initation after time of storage....................................43 TECHNICAL SPECIFICATIONS - CHASSIS...........................44 TECHNICAL SPECIFICATIONS - ENGINE ..........................46 HEAD WORD INDEX ..........................................................48 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. 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. 1 OPERATION INSTRUMENTS Clutch lever The clutch lever 1 is fitted on the left hand side of the handle bar. When engine is cold, there should allways be a play of 1­3 mm (0,04­0,1 in) at this lever (measured at outer edge). 1-3 mm 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 handlebar on the right and actuates the front wheel brake. ENGLISH 5 Engine number, engine type 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. Display TEST When you switch on the ignition, all of the display elements will light up for 1 second for the function test. ENGLISH 6 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. 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 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). 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. ENGLISH 7 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. 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 33): ­ 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. 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. ENGLISH 8 3 4 2 Choke lever If the choke lever 3 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. 4 mm. Ignition lock with 3 switch positions Switch positions of ignition lock 4: Ignition off, (engine can't be started) Ignition on, (engine can be started) Ignition off, handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar all the way to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and . Combination switch 4 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 1 2 3 Starter tip switch, emergency OFF tip switch, light switch 6 Use the starter tip switch 5 to operate the electric starter. The light switch has 3 positions: = Light off = Parking light on = Headlight on 5 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). Filler cap 7 The filler cap 7 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. ENGLISH 9 Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the twist grip 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, approximately 2.5 liters, 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. 10 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. NO NO NO ENGLISH OFF RES FUEL ON RES FUEL RES RES FUEL O FF O FF O FF 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). 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 0518X730 .............20 Klicks (640 LC4) WP 1418X738 .............20 Klicks (640 LC4 Supermoto) A 1 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. 2 2 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 0518X730 .............12 Klicks (640 LC4) WP 1418X738 .............15 Klicks (640 LC4 Supermoto) 11 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 0118X729 .............Position 3 WP 0118X730 .............Position 4 (640 LC4) (640 LC4 Supermoto) 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. 4 BASIC SETTING: WP 0118X729 .............Position 7 WP 0118X730 .............Position 8 (640 LC4) (640 LC4 Supermoto) WARNING ­ NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS. ­ THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT. Holding bars The passenger can hold on to the holding bars on the rear end of the vehicle. ENGLISH Rebound damping of fork 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. ­ ­ ­ ENGLISH 12 ­ ­ ­ ­ ­ ­ 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 LC4 16:42 Z 35 kmh 50 kmh 70 kmh 90 kmh 100 kmh LC4 SUPERMOTO 17:42 Z 35 km/h 55 km/h 75 km/h 90 km/h 100 km/h 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. 13 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 1 2 3 4 5 6 7 Open the fuel tap 1 Switch on ignition (turn ignition key 2 into position ). Switch on emergency OFF switch 3. Switch transmission to idle (green indicator lamp N 4 lights up). Operate cold starting device (choke) 5. Do not accelerate; operate starter button 6. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Take the motorcycle off of the main stand or side stand. 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 ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING. ­ ENGLISH 14 4 CAUTION ! ! ­ 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. 2 3 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 LC4 / LC4 SUPERMOTO: 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. Motorcycles with side stands are also equipped with a safety starting system. If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop. 6 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 ). Switch on emergency OFF switch 3. Switch transmission to idle (green indicator lamp N 4 lights up). Do not accelerate; operate starter button 6. Take the motorcycle off of the main stand or side stand. What to do when the engine is ,,flooded" The throttle must be fully opened when starting. If necessary change sparkplug. 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. ! ­ HIGH CAUTION ! ­ ­ ­ ­ ­ 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 MAIN STAND HAS BEEN SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL. 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 CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE CONTROL OVER YOUR MOTORCYCLE. WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION AND . LOCK TO POSITIONS 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. ­ ­ 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 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 OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL. LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO ENGINE DAMAGE. NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER. OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR. THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT TEMPERATURE HAS REACHED 105°C. 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 LEFT RADIATOR IS NOT RUNNING -IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOCITIES 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 COLING 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 BOLTS ARE TIGHT. 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. 15 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 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 ­ ­ ­ IN THE RAIN, OR AFTER THE MOTORCYCLE HAS BEEN WASHED, BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS. FIRST, THE BRAKES MUST BE BRAKED DRY. ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN. 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. ENGLISH Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Turn the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle. WARNING ­ ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE. ­ NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING. ­ 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. ENGLISH 16 35 mm ! ­ CLOSE ­ CAUTION ! THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE. ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS. INFORMATION ABOUT THE SIDE STAND: Use your foot to push the side stand forward as far as possible, and lean your motorcycle to the side. Make sure that your motorcycle is standing safely on solid ground. Just in case, you can also put in a gear. ! THE CAUTION ! SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY. IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE STAND, YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME, AND YOUR MOTORBIKE MAY FALL OVER. NOTE REGARDING THE CENTER STAND:(is available as an accessory) We advise 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 motorcycle backwards at an angle as illustrated (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely. ! THE CAUTION ! CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY. BY SITTING ON THE MOTORCYCLE, YOU WILL PUT ADDITIONAL WEIGHT ON THE CENTER STAND, POSSIBLY CAUSING THE CENTER STAND OR FRAME TO BE DAMAGED OR THE MOTORCYCLE TO FALL DOWN. Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher. ! USE CAUTION ! LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. 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.). 17 ENGLISH PERIODIC MAINTENANCE SCHEDULE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Make sure all screws and nuts are tight. Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check screws of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear, force fit and tension. Check screws on pinion and chain sprocket for locking devices and a tight fit. Lubricate chain Check wheel bearings and jerk damper for play 640 LC4 640 LC4 SUPERMOTO 2. Service after 1. Service 5000 km, then after every 5000 km or 1000 km once a year 18 ADD-ON-PARTS CARBURETOR ENGINE CHASSIS BRAKES WHEELS ENGLISH IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year every 2 years or 20000 km IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box (depending on the dirt accumulation) Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running. Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all screws, nuts, and hose clamps for their tight fit before each start after every cleaning for cross country use once a year 19 ENGLISH