BEDIENUNGSANLEITUNGOWNER’S HANDBOOKMANUALE D’USOMANUEL D’UTILISATIONMANUAL DE INSTRUCCIONES

ART. NR. 3.205.309.97

400/620SX/SC/EGS

’98

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IMPORTANT

WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL

CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST

RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE

WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY.

IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO

NOTICES THAT ARE MARKED AS FOLLOWS:

� WARNING �IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOURBODY AND YOUR LIFE.

! CAUTION !IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGETO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

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

Frame number

Engine number

Stamp of dealer

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITEDOwners are warned that the law may prohibit:(a) The removal or rendering inoperative by any person other than for purposes of mainten-

ance, repair or replacement, of any device or element of design incorporated into anynew vehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or ren-dered inoperative by any person.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

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Introduction

We would like to congratulate you on your purchase of a KTM motorcycle. Let us alsotake this opportunity to thank you for putting your trust in us; we will not let you down.

You are now owner of a sporty and modern motorcycle which you are bound to have agreat time with provided you care for it properly. Your owner’s handbook will furnish youwith important information on how to operate and maintain your new KTM motorcycle.At the time of printing, the handbook covered the most up-to-date models in this series.It is, however, possible that we may have made slight modifications in the meantime dueto development in our motorcycle design.

Many motorcyclists have a good working knowledge of motorcycle mechanics; if this istrue in your case, you will be able to use this manual to carry out most of the mainten-ance steps yourself. If, on the other hand, you are not very familiar with motorcycles, itmight be better to have a professional KTM dealer perform those steps marked by *found in the chapter entitled “Maintenance Work on Chassis and Engine” of this manual.

Take special care to follow the recommended run in, inspection, and maintenance inter-vals. Heeding these guidelines will significantly increase the life of your motorcycle. Besure to have any maintenance jobs performed by an authorized KTM dealer.Address your special requests to an authorized KTM dealer who, should the need arise,will be supported by the KTM importer.

We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG5230 MATTIGHOFEN, AUSTRIA

Attachments for the models SX and SC: 1 spare parts manual chassis1 spare parts manual engine1 owner handbook for WP Extreme fork1 owner handbook for WP shock absorber

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

KTM Austria’s certificate of achievement for itsQuality System ISO 9001 is the beginning of anon-going total re-engineering quality plan for abrighter tomorrow.

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Page

SERIAL NUMBER LOCATING .....................................................4Frame number ........................................................................4Engine number, Engine type....................................................4

OPERATION INSTRUMENTS .....................................................4Clutch lever ............................................................................4Hand decompression lever.......................................................4Choke lever (EGS)...................................................................5Hand brake lever.....................................................................5Speedometer, control lamps (SC) .............................................5Odometer (SC - USA) ..............................................................5Speedometer, control lamps (EGS)...........................................5Ignition lock............................................................................6Short circuit button (SX)..........................................................6Combination switch (SC).........................................................6Combination switch (SC - Aus, SGP) .......................................6Flasher switch (SC) .................................................................6Combination switch (EGS) ......................................................7Emergency OFF switch (EGS)..................................................7Filler cap .................................................................................7Fuel ........................................................................................8Fuel tap...................................................................................8Choke (SC) .............................................................................8Hot start device.......................................................................9Shift lever ...............................................................................9Kickstarter ..............................................................................9Foot brake pedal......................................................................9Handlebar lock........................................................................9Compression damping of fork ................................................10Rebound damping of fork ......................................................10Compression damping of shock absorber................................10Rebound damping of shock absorber......................................10Baggage rack .........................................................................10

DRIVING INSTRUCTIONS ........................................................11

PERIODIC MAINTENANCE-SCHEDULE ...................................14

MAINTENANCE WORK ON CHASSIS AND ENGINE ...............15Removal of seat (SX, SC) .......................................................15Removal of seat (EGS) ...........................................................15Tool set.................................................................................16Breather plugs front fork........................................................16Check and adjust steering head bearing .................................16Changing the spring preloading of the shock absorber ............17Lubricate rear suspension linkage ..........................................17Checking rubber ring on the WP rear shock absorber.............17Check chain tension..............................................................18Correct chain tension ............................................................18Chain maintenance ...............................................................18Chain wear ...........................................................................19General informations about KTM disc brakes .........................19Checking of free travel at the hand brake lever ......................19Checking of brake fluid level - front brake..............................20Refilling the front brake fluid reservoir ...................................20Check the front brake pads....................................................20

Replacing front brake pads.....................................................20Changing the basic position of the brake pedal .......................21Check the rear brake fluid level .............................................21Refilling the rear brake fluid reservoir ....................................21Checking the rear brake pads ................................................22Replacing the rear brake pads ................................................22Dismounting and mounting the front wheel (SX, SC) .............22Dismounting and mounting the front wheel (EGS).................23Dismounting and mounting the rear wheel ............................23Checking the cush drive rubbers in the rear wheel hub (EGS).....24Tyres, air pressure .................................................................24Checking spoke tension.........................................................25Battery (A, CH) .....................................................................25Fuse parking light (A, CH) .....................................................25Fuse fan (EGS) ......................................................................25Replacing the headlight bulb (EGS) ........................................26Replacing the parking light bulb (EGS) ...................................26Cooling system (SX, SC) ........................................................26Cooling system (EGS)............................................................27Coolant level check...............................................................28Cleaning the air filter.............................................................28Exhaust system .....................................................................28Carburetor – Adjust idling (DellOrto)....................................29Adjust hot start device...........................................................29Check float level ...................................................................29Checking axial play of float....................................................29Adjusting the throttle cable (SX, SC) ......................................30Adjusting the throttle cable ( EGS).........................................30Adjusting the choke cable (SX, SC) ........................................30Adjusting the choke cable (EGS) ............................................31Adjusting the clutch cable .....................................................31Checking the adjustment of the hand decompression cable ....31Engine oil..............................................................................31Checking the engine oil level.................................................32Oil circuit (SX, SC) ................................................................32Changing the engine oil (SX, SC) ...........................................33Replacing and bleeding the microfilter (SX, SC)......................33Oil circuit (EGS)....................................................................33Changing the engine oil (EGS)...............................................34Changing the fine screen filter (EGS) .....................................34Changing oil filter..................................................................35

TROUBLE SHOOTING ..............................................................36

CLEANING ...............................................................................38

CONSERVATION FOR WINTER OPERATION...........................38

STORAGE..................................................................................38Re-initation after time of storage ............................................38

TECHNICAL SPECIFICATIONS - CHASSIS................................39

TECHNICAL SPECIFICATIONS - ENGINE ...............................40

WIRING DIAGRAMME ................................................APPENDIX

Index

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Chassis numberThe chassis number is stamped on the right side of the steering head tube. Writethis number into the relevant area on page 1.

Engine number, engine typeThe engine number and engine type are stamped on the right hand side of theengine below the chain sprocket. Write this number into the relevant area onpage 1.

Clutch leverThe clutch lever 1 is fitted on the left hand side of the handle bar. When engineis cold, there should allways be a play of 1–3 mm (0,04–0,1 in) at this lever (mea-sured at outer edge).

! CAUTION !IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE CLUTCH

WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS.

Hand decompression leverThe hand decompression lever 2 is only used in two special cases:a) When the engine stalled.

When you then start the engine, you may feel a hard resistance on the kickstar-ter, because the automatic decompressor cannot lock into place. If this happens,pull the hand decompression lever and stand on the kickstarter. You can thenstart the engine normally again.

b) When you want to push-start the motorcycle.While pushing, pull the decompression lever to make it easier to get the enginegoing.

! CAUTION !THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED. A LACK OF

PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE.

1-3 mm

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2

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

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Choke lever (EGS)If the choke lever 1 is pulled backwards, a bore will be opened in the carburetorthrough 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 upto the stop, the bore will be closed again. In this position the choke cable musthave a play of approx. 2mm.

! CAUTION !IF THERE IS NO PLAY IN THE CHOKE CABLE, THE COLD STARTER SYSTEM CANNOT BE COMPLE-TELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN UNEVEN RUNNING ENGINE,AN EXTREME WEAR OF PISTON AND CYLINDER.

Hand brake leverThe hand brake lever is mounted on the handle bars on the right and actuates thefront wheel brake.

� 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 LOO-KED OVER BY A KTM DEALER.

Speedometer, control lamps (SC)The mileage indicator A in the speedometer 2 indicates overall mileage.

The green control lamp flashes when the indicator is working in the samerhythm as the flashing indicator.

The blue control lamp lights up when the high beam is on.

The red cooling liquid temperature warning lamp lights up at a coolingliquid temperature of 110°C.

! CAUTION !PAY ATTENTION TO THE DIRECTIONS IN THE CHAPTER „COOLING SYSTEM“ ON PAGE 26.

Odometer (SC - USA)The odometer is a mileage indicator and can be set to 0 by means of the adjust-ment wheel 3.

Speedometer, control lamps (EGS)The mileage indicator B in the speedometer 4 indicates overall mileage. The daymileage indicator C can be set to 0 by means of the adjustment wheel D. Turnthe adjustment wheel forward until only zeros can be seen in the display.

The green control lamp flashes when the indicator is working in the samerhythm as the flashing indicator.

The green control lamp lights up when the gear is switched to idle.

The blue control lamp lights up when the high beam is on.

The red cooling liquid temperature warning lamp lights up at a coolingliquid temperature of 110°C.

! CAUTION !PAY ATTENTION TO THE DIRECTIONS IN THE CHAPTER „COOLING SYSTEM“ ON PAGE 27.

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Ignition lockSwitch positions of ignition lock 1:OFF = Ignition off, light offPARK = Ignition off, parking light on (only versions with battery)ON 1 = Ignition on, light on (if engine is running)ON 2 = Ignition on, light on (if engine is running)The ignition key can be withdrawn in positions OFF and PARK.

Short circuit button (SX)The short circuit button 2 turns off the engine. When pressing this button, theignition circuit is short-cicuited.

Combination switch (SC)The light switch has 3 switch positions.A = Light offB = Low beam lightC = High beam lightThe red short circuit button 3 serves to switch off the engine. Leave the switchpressed, until the engine stops. With the button 4 the horn will sound.

Combination switch (SC - Aus, SGP)The light switch has 3 switch positions.B = Low beam lightC = High beam lightThe red short circuit button 3 serves to switch off the engine. Leave the switchpressed, until the engine stops. With the button 4 the horn will sound.

Flasher switch (SC)

Flasher left

Flasher right

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3 4

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3 4

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Combination switch (EGS)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 indicatorswitch towards switch housing to switch off the indicator.The horn is sounded with button 3. The light signal (high beam) is actuated with button 4.NOTE: The engine must be running in order to check that the electric compo-nents are functioning correctly.

Emergency OFF switch (EGS)The emergency OFF switch 5 is mainly a safety and emergency switch andshould normally be ON.

When this symbol is concealed by the switch, the ignition circuit will beshort-circuited.

When this symbol is concealed by the switch, the ignition circuit will beoperative and the engine should start when cranked.

The Button 6 is inoperative.

Filler capTo open filler cap: Pull the tank venting hose 7 from the steering head and turnthe filler cap counter-clockwise.To close filler cap: Screw on the filler cap clockwise. Place the tank venting hose 7in the steering head, avoiding any kinks.

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ignition circuitshort-circuited

engine does not start

ignition curcuitoperative

engine can be start

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FuelThe LC4 engine needs premium gasoline with an octane number of 95 or higher.

! CAUTION !USE 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 DOC-TOR’S ADVICE IMMEDIATELY.

Fuel expands when its temperature rises. Therefore do not fill the tank to the top(see fig.).

Fuel tapOFF 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 posi-

tion. Now fuel may flow to carburetor. In this position the tank emptiesdown to the fuel reserve of approx. 1,5 liters.

RES The reserve tank, approximately 1,5 liters, cannot be tapped until the rota-ting handle is turned to the RES position. Fill the tank as soon as possibleand remember to turn the rotating handle back to the ON position so thatyou will have backup fuel next time, too.

! CAUTION !THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS

NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.

Choke (SX, SC)In these models the choke operating element is located on the engine. Pull theknob 1 and turn it (approx. 90°) to open a bore in the carburetor through whichthe engine can take in additional fuel. The result is a „fat“ fuel-air mixture of thetype needed for cold starts.To close the bore in the carburetor, turn the knob again (approx. 90°); the knobmoves back into its initial position. In this position, the play of the choke cablemust be approximately 2 mm (0.1 in).

! CAUTION !IF THERE IS NO PLAY IN THE CHOKE CABLE, THE COLD STARTER SYSTEM CANNOT BE COMPLE-TELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN UNEVEN RUNNING ENGINE,AN EXTREME WEAR OF PISTON AND CYLINDER.

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OFF ON RES

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Hot-start deviceThe carburetor is equipped with a hot-start device which makes it easier to startthe engine when hot. Press the hot-start button 1 until it engages. This willslightly lift the throttle valve. Once the engine is running, pull the hot-start buttonback into its original position.NOTE:Always pull the hot start device back into the initial position as soon as the engineis running. An activated hot starting device will have a negative impact on thecold starting properties of the engine.

Shift leverThe shift lever is mounted on the left side of the engine. The position of the gearsis shown in the illustration. Neutral, or the idle speed, is located between first andsecond gear.

KickstarterThe kickstarter is mounted on the left side of the engine. Its upper part can beswivelled.

� WARNING �WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES.YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT

VEHEMENTLY ENOUGH.

Foot brake pedalThe foot brake pedal is disposed in front of the right foot rest. Its basic positioncan be adjusted to your seat position (see maintenance work).

� 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 LOO-KED OVER BY A KTM DEALER.

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 rightand withdraw.

! CAUTION !NEVER LEAVE THE KEY INSERTED IN THE LOCK. IF YOU TURN THE STEERING TO THE LEFT THE

KEY COULD GET DAMAGED.

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Compression damping of fork The compression damping mechanism is built into the left fork tube. It only regu-lates the degree of damping during compression.By using the knob 1 (COM), the degree of damping of the compression can beadjusted. Turn the knob clockwise to increase damping, turn it counterclockwiseto reduce damping during compression.

BASIC SETTING:– turn rotary knob clockwise as far as it will go– turn it back by as many clicks as are specified for the relevant type of fork– WP09.18.S7.40 8 clicks

WP09.18.S7.44 12 clicksWP06.18.Q7.12 (K4T96L3) 10 clicks

Rebound damping of forkThe rebound damping mechanism is built into the right fork tube. It only regulatesthe degree of damping during rebounding.By using the knob 2 (REB), the degree of damping of the rebound can be adju-sted. Turn the knob clockwise to increase damping, turn it counterclockwise toreduce damping during rebounding.

BASIC SETTING:– turn rotary knob clockwise as far as it will go– turn it back by as many clicks as are specified for the relevant type of fork– WP09.18.S7.40 12 clicks

WP09.18.S7.44 12 clicksWP06.18.Q7.12 (K4T96L3) 14 clicks

Compression damping of shock absorberWith the knob 3 the degree of damping of the compression can be adjusted to 7positions. Turn the knob counterclockwise to increase damping, turn it clockwiseto reduce damping during rebounding.

WP01.18.S7.98 3WP01.18.Q7.82 3WP01.18.Q7.81 (K4T96S) 3

Rebound damping of shock absorberWith the setting wheel 4 the degree of damping of the rebound can be adjustedto 11 positions. Turn the knob to the left side to increase damping, turn it to theright side to reduce damping during rebounding.

WP01.18.S7.98 5WP01.18.Q7.82 4WP01.18.Q7.81 (K4T96S) 4

� WARNING �– NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS.– THE DAMPING UNITY OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN.

NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK

YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

Baggage rack (EGS)The baggage rack may be loaded with up to 10 kg. The two lateral hoops serve ashandles for the passenger

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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.– Familiarize yourself with the operating elements.– Adjust the hand brake lever and foot brake lever to the most com-

fortable positions for you.– Get used to handling the motorcycle on an empty parking lot or

open space, before starting on a longer drive. Also try to drive asslowly as possible and in standing position, to improve your fee-ling for the vehicle.

– Do not drive along off-road tracks which go beyond your abitilyand experience.

– Hold the handle bars with both hands and leave your feet on thefoot rests while driving.

– Remove your foot from the foot brake lever when you are notbraking. If the foot brake lever is not released the brake pads rubcontinuously and the braking system is overheated.

– A passenger is allowed only if your motorcycle is fitted and regi-stered for such purposes. The passenger must hold tight to thestrap or hold on to the driver during the drive, with his feet onthe passenger foot rests.

– Do not make any alterations to the motorcycle and always useORIGINAL KTM SPARE PARTS. Spare parts from other manufac-turers can impair the safety of the motorcycle.

– Motorcycles are sensitive to alterations in the distribution ofweight. If you are taking luggage with you, this should be securedas close as possible to the middle of the vehicle; distribute theweight evenly between the front and rear wheel. Never exceedthe maximum permissible laden weight and the axle weights.The maximum permissible laden weight is made up of the follo-wing components:– Motorcycle ready for operation and tank full– Luggage– Driver and passenger with protective clothing and hemlet.

– Pay attention to running-in procedure.

Running in the LC-4 modelsEven very precisely machined sections of engine components haverougher surfaces than components which have been sliding acrossone another for quite some time. Therefore, every engine needs tobe broken in. For this reason, during its first 1000 kilometers (620miles) the engine must not be revved up to its performance limits.The engine speed of 4800 r.p.m. must not be exceeded during thefirst 1000 kilometers (620 miles). During this break-in time, youshould ride your motorcycle in different conditions (roads, easy off-road terrain). The following table shows you the maximum velocityvalues in the different gears at 4800 r.p.m. as based on the rearwheel transmission ratio of your motorcycle.

km/h (mph)NOTE:During the stage of running the engine in, that is the first 1000 KM(620 miles), the engine oil used should be of a mineral oil (non syn-thetic) formula. This also applies if the engine has been repaired.

Check the following before each startWhen you start off, the motorcycle must be in perfect mechanicalcondition. For safety reasons, you should make a habit of performingan 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 toengine damage.

2 FUELCheck that there is sufficient fuel in the tank; when closing thefiller cap, check that the tank venting hose is free of kinks.

3 CHAINA loose chain can fall from the chain wheels; an extremely wornchain can tear, and insufficient lubrication can result in unneces-sary wear to the chain and chain wheels.

4 TIRESCheck for damaged tires. Tires showing cuts or dents must bereplaced. The tread depth must comply with the legal regulations.Also check the air pressure. Insufficient tread and incorrect airpressure deteriorate the driving performance.

5 BRAKESCheck correct functioning of the braking system. Check for suffi-cient brake fluid in the reservoir. The reservoirs have been desi-gned in such a way that brake fluid does not need to be refilledeven when the brake pads are worn. If the level of brake fluidfalls below the minimum value, this indicates a leak in the bra-king system or completely worn out brake pads. Arrange for thebraking system to be checked by a KTM specialist, as completefailure of the braking system can be avoided.Also check the state of the brake hose and the thickness of thebrake linings.Check free travel at hand brake lever and foot brake lever.

6 CABLESCheck correct setting and easy running of all control cables.

7 COOLING FLUIDCheck the level of cooling fluid when the engine is cold.

8 ELECTRICAL SYSTEMCheck correct functioning of headlamps, tail-lights, brake lights,indicators, control lamps and horn while the engine is running.

9 LUGGAGEIf you are taking luggage with you, check that this is securelyfastened.

� 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.– ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAM-

PLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE

MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRI-BUTION 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.

� WARNING �IMPORTANT INSTRUCTIONS FOR MODELS SX AND SC:– THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY -

NO ADDITIONAL PASSENGER ALLOWED!– NEITHER DO THE SX-MODEL MEET THE APPLICABLE STATUTORY REGULATI-

ONS AND SAFETY STANDARDS. USING THEM ON PUBLIC ROADS, HIGH-WAYS, FREEWAYS ETC. IS AGAINST THE LAW.

– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT OTHER

PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.

DRIVING INSTRUCTIONS

16:40 t 15:40 t 16:45 t 15:45 t 15:50 t 14:50 t

1st 40 (25) 40 (25) 35 (22) 35 (22) 30 (19) 30 (19)

2nd 55 (34) 55 (34) 50 (31) 50 (31) 40 (25) 40 (25)

3rd 75 (46) 70 (43) 65 (40) 65 (40) 60 (37) 55 (34)

4th 90 (56) 85 (53) 80 (50) 80 (50) 70 (43) 65 (40)

5th 115 (71) 110 (71) 100 (62) 100 (62) 85 (53) 80 (50)

gear i

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Starting when the engine is cold1 Open the fuel tap 12 Switch on the ignition 2 and the emergency OFF switch 3.3 Swing up the side stand or center stand.4 Put the gear in neutral5 Operate the choke 46 Leave throttle closed and push the kickstarter hard ALL THE WAY.7 If the engine starts, push the choke lever back a little bit, as soon as the engine

runs unevenly.

� WARNING �– TO AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR BOOTS!– 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 PRO-VIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

! CAUTION !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.

Starting when the engine is warm1 Open the fuel tap 12 Switch on the ignition 2 and the emergency OFF switch 3.3 Swing up the side stand or center stand.4 Put the gear in neutral5 Leave the throttle closed and push the kickstarter hard ALL THE WAY

Starting when the engine is hot1 Open the fuel tap 12 Switch on the ignition 2 and the emergency OFF switch 3.3 Swing up the side stand or center stand.4 Put the gear in neutral5 Push in the hot-start button 5 on the carburettor as far as it will go6 Leave the throttle closed and push the kickstarter hard ALL THE WAY7 Once the engine is running, pull hot-start button back into its original position.

What to do when the engine is „flooded”Pull in the hand decompression lever, open the throttle fully, kick the kick starterthrough the stroke 5 to 10 times and start the motor as described above.

Starting offPull the clutch lever. Put the engine into first gear, slowly release the clutch leverand open throttle at the same time.

� WARNING �BEFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG UP FULLY.IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL.

Shifting/RidingYou are now in first gear, refered to as the drive or uphill gear. Depending on theconditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, atthe same time pull clutch lever in and shift to the next higher gear. Let clutchlever go again and give gas. If you turned on the choke, make sure you turn it offagain as soon as engine is warm.When you reach full speed through opening the throttle all the way, turn throttleback to 3/4; the speed hardly decreases although the engine will use less gas. Only give as much gas as the engine can handle. Through quick and high revingof throttle, the gas usage increases.

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By shifting down, use the brakes if necessary and close throttle at thesame time. Pull clutch lever and shift down to the next gear. Letclutch lever go slowely and open throttle or shift down again.

� WARNING �– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO

LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECO-GNIZED AS EARLY AS POSSIBLE.

– ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR

DRIVING SKILLS.– DRIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.– 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.– REPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR DAMA-

GED. IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR LENS,THE OPERATOR WILL BE BLINDED.

– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.

! CAUTION !– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT

ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN

A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO

WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED

BE TAKEN. THE ENGINE HAS REACHED 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. INADDITION, 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 THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP

WHILE YOU ARE DRIVING, PLEASE PROCEED AS SPECIFIED IN THE NOTES

CONTAINED ON PAGES 26 (SX, SC) AND 27 (EGS)!– 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.

BrakingClose throttle and apply the hand and foot brakes at the same time.When driving on sandy, wet or slippery ground use mainly the rearwheel brake. Always brake with feeling, blocking wheels can causeyou to skid or fall. Also change down to lower gears depending onyour speed.When driving down hill, use the braking effect of the engine.Change down one or two gears but do not overspeed the engine. Inthis way, you will not need to brake so much and the brakes will notoverheat.

� WARNING �WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND

BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRA-KING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL.

Stopping and parkingApply the brakes fully and put the engine into neutral. To stop theengine, switch off the ignition or pull the short circuit button whenthe engine is idling, until the engine stops. Turn the fuel tap to theOFF position, park on an area where the ground is firm, and lock themotorcycle.

� WARNING �– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE

IS RUNNING.– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-

NING. 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.

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE

SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.

! CAUTION !– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE

CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE.– NEVER LET THE PARKING LIGHT ON FOR LONGER THAN 90 MINUTES IF

THE ENGINE IS SWITCHED OFF! IF THE OPERATING TIME EXTENDS THIS

LIMIT, THE BATTERY WILL BECOME TOTALLY DISCHARGED AND THUS DEST-ROYED (ONLY MODELS WITH BATTERY).

– ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE

SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

NOTE REGARDING THE MAIN STAND:We advise the following procedure to place the motorcycle on themain stand as effortlessly as possible:a) press main stand to ground using footb) swing out kickstarter and pull at an angle toward the rear of

motorcycle (see illustration)

NOTE REGARDING THE SIDE STAND:Use your foot to kick side stand forward up to the stop and lean themotorcycle sideways. Make sure that the ground is solid and thatyour motorcycle is standing securely. Just in case, you can shift intofirst gear.

! CAUTION !THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE.THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED AND THE MOTORCY-CLE CAN FALL OVER IF YOU MOUNT THE MOTORCYCLE, THUS PUTTING AN

ADDITIONAL LOAD ON THE SIDE STAND.

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Check engine oil level �

Change engine oil (SX, SC) � � �

Change engine oil (EGS) � � �

Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil �

Change oil filter unit � � �

Change microfilter (SX, SC) � �

Change fine screen filter (screwed filter) at the frame tube � � �

Check oil lines for leakage and proper instalment � �

Check valve clearance � �

Clean spark plug and adjust electrode gap �

Change spark plug after 10 000 kilometers (6 200 miles)Check valve clearance �

Drain and clean carburator float bowl � � �

Adjust idling �

Check breather hoses of engine gase and gas tank for correct position without buckles � �

Clean air filter and air filter box � � �

Check sprockets, chain guides and chain for wear � � �

Maintaining chain tension eccentrics (Duke) �

Clean and lube chain � � �

Check chain tension � � �

Check cooling liquid level � � �

Check quality of antifreeze �

Check cooling system for leaks � � �

Check exhaust system for leakage �

Change exhaust muffler packing (aluminium-muffler) � �

Check exhaust brackets � �

Disassemble and clean spark arrestor discs (USA models)Check brake fluid level front and rear � � �

Change brake fluid �

Check brake pad thickness � �

Check brake discs �

Check condition and correct instalment of brake hoses � � �

Check freeplay and easy operation of hand brake lever and foot brake lever � � �

Check adjustment and function of fork � �

Check fork for leaks �

Loosen breather screws at fork legs (overpressure) �

Change fork oil �

Perform a full maintenance job for the telescopic fork �

Clean dust scrabber on forks � � �

Check steering head bearing clearance / adjust � �

Clean and grease steering head bearings and its seals �

Check adjustment and funktion of shock absorber � �

Check O-ring of the shock absorber for wear � �

Servicing the shock absorber �

Grease lubricating nipple of the Pro Lever suspension system �

Disassemble the Pro Lever suspension system and perform a full maintenance job on it �

Servicing swingarm pivots �

Check tightness of spokes and rim join � � �

Check wheel bearings for clearance � �

Check chock absorber rubbers on the rear wheel hub �

Check tire condition and air pressure � �

Check cables for damage and easy working � �

Lube and adjust cables � � �

Check the electrical system � � �

Check battery holder and connections (Duke) � �

Check adjustment of head light �

Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray � �

Check all screws, nuts and hose clamps for proper tightness � � �

Grease or lube all pivot points and sliding components � � �

PERIODIC MAINTENANCE SCHEDULE

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IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING ORCOMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO

BE CARRIED OUT AFTER EACH RIDE OR RACE

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� WARNING �ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALISTKNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER

! CAUTION !– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CARBURETTOR,

ELECTRIC CONNECTORS ETC.– WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE

FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, BE AWARE OF ANY LEAKING FUEL FROM THE CARBURETOR OR FUEL TANK

– DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE.INSTEAD, USE SELF-LOCKING NUTS.

– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.– REMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.– UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES

1.000.000 LITERS WATER.

Removal of seat (SX, SC)By using the quick-release fastener 1, the seat can be removed without usingtools. Turn the quick-release fastener about 180° counter clockwise and lift upthe rear of the seat. Pull the seat backwards and unhook it from the front fastenerscrew 2. When installing the seat, be sure to insert the rear portion of the seatinto the metal clasp 3.

Removal of seat (EGS)Remove the attachment screws 4 from the underside of the fender. Lift the rearof the seat, pull backwards, and unhook it from the fastener screw 2. To installthe seat, hook the seat into the attachment screw, set the rear portion down onthe frame, and slide it forward. If necessary, press down on the front area of theseat so that the seat catches on the metal clasp 3. Insert and tighten the attach-ment screws.

12

3

4

MAINTENANCE WORK ON CHASSIS AND ENGINE

1

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Tool set (SC)The tool set 1 is located at the bottom of the seat.

Tool set (EGS)The tool set 2 is located in the tool box under the right side cover.

Breather plug front forkAfter every 5 hours of use for competitive racing, slacken the breather plugs 3 afew turns in order to relieve excess pressure from the inside of the fork. To dothis, place the motorcycle on a stand with the front wheel lifted off the ground.When riding the motorcycle mainly on street, it will be enough to have this jobperformed in the course of the periodical maintenance service.

! CAUTION !EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF YOUR

FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE

SEALS REPLACED.

Check and adjust steering head bearing*Check steering head bearing for play periodically. To check this put motorcycle ona stand so that the front wheel is off the ground. Now try to move the fork for-ward and backward. To adjust, loosen the five pinch bolts 4 of the top tripleclamp and turn steering stem bolt clockwise 5 until there is no more play. Don’ttighten the steering stem bolt all the way, otherwise the bearings will be dama-ged. With a plastic hammer, lightly rap on the triple clamp to release tension. Re-tight the five pinch bolts.WP Extreme fork:.................................15 NmWP USD (UpSideDown) fork: ...............15 Nm

� WARNING �IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE WILL

SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL.

! CAUTION !IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, FIRST THE BEA-RINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.

At least once a year, the steering head bearings should be smeared with water-proof grease.

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3 3

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Changing the spring preloading of the shock absorberKTM sets the shock absorber for a driver only, weighing approximately 75 kg(165 lb). If you want to take a passenger with you, of if you weigh considerablymore or less than 75 kg (165 lb), you should change the spring preloading Aaccordingly. This is easily done.NOTE:– Before changing the spring preload note down the basic setting, e.g. how many

threads are visible above the adjusting ring.– One rotation of the adjusting ring 2 changes the spring pretension by approxi-

mately 1,75 mm (0,07 in).Loosen the locking ring 1 with the hook spanner from the tool set. Change thespring preload with the adjusting ring 2 and re-tighten the locking ring.

BASIC SETTING – SPRING PRELOADSX: 17 mm (0.7 in) / SC, EGS: 23 mm (0,9 in)

Lubricate rear suspension linkageThe bearings in the link lever must be greased in regular intervals. For this pur-pose, a lubricating nipple 3 is mounted on the link lever.

! CAUTION !AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALY IMPORTANT TO GREASE

THE LUBRICATING NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.

Checking rubber ring on the WP rear shock absorberA rubber ring mounted on the rear shock absorber serves as a vibration damper.This ring gets pressed together with time and loses its shock absorbing quality. Measure the distance between the two discs at various points around their cir-cumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubberring replaced by an KTM dealer when compaction due to wear has exceeded thislower limit.

! CAUTION !NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK

ABSORBER.

� WARNING �THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN.NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK

YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

3

min. 2,5 mm

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Checking chain tension– For checking, put the motorcycle on its main stand or jack it up on its frame so

that the rear wheel is relieved of any load.– Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sliding

component until the upper part of the chain is tensioned (see illustr.)– Now, the distance A between chain and swingarm should be 0 mm respec-

tively 5 mm (0,2 in) (depending on final drive ratio). The upper part of thechain B must be tight (see illustr.).

– Correct chain tension, if necessary!

� WARNING �– IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION (CHAIN,

SPROCKETS, DRIVE ASSEMBLY AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO UNNECES-SARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN JUM-PING OFF THE SPROCKETS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK THE REAR

WHEEL OR DAMAGE THE ENGINE. – IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

Correct chain tension– Loosen collar nut 1, loosen lock nuts 2, and turn right and left adjusting screws 3

equally far. Tighten lock nuts 2. – Before tightening the collar nut, verify that the chain adjusters 4 are sitting

close to the adjusting screws and that the rear wheel has been aligned with thefront wheel.

– Tighten fcollar nut 1 with 80 Nm (59 ft.lb).

Chain maintenanceFor long chain life, good maintenance is very important. Chains without O-ringsshould be cleaned in fireproof solvent regularly and afterwards treated with hotgrease or chain spray (Shell Advance Bio Chain).O-ring chains on the other hand are very simple to clean. The best way is to uselots of water, but never use brushes or cleaning liquids. After letting the chain dry,you can use a special O-ring chain spray (Shell Advance Bio Chain).

� WARNING �NO LUBRICATION IS ALLOWED TO REACH THE REAR TYRE OR THE BRAKE DISKS, EITHERWISE

THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDU-CED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.

! CAUTION !WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK CLIP

MUST POINT IN RUNNING DIRECTION.Also check sprockets and chain guides for wear, and replace if necessary.

✓

A

B

15:4015:45 A = 0mm16:4016:4514:50 A = 5mm15:50

30mm

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2

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Chain wearIn order to check the chain wear, regard the following indications:Shift the gear into idling and pull the upper chain strand with approx. 10-15 Kilo-gramm (33 lb) upwards (see figure). Now one can measure a space of 18 chainreels at the lower chain strand. The chain should be replaced at the latest when aspace of 272 mm (10,70 in) is measured. Chains do not always wear off evenly,therefore repeat the measurement at different places on the chain.NOTE:If you mount a new chain, the sprockets should also be replaced. New chainswear faster if used on old used sprockets.

General information about KTM disc brakesBRAKE CALIPERS:The brake calipers of this series use a „floating” mount. This means that the brakecalipers are not solidly attached to the caliper support, which enables them to„float” for maximum braking contact.

BRAKE PADS:The motorcycles are delivered with organic brake pads and have also been type-coded with these pads. Said pads are suitable for almost the entire range of appli-cation of these motorcycles.It is only for competitive racing in extremely dirty conditions (e.g., water in com-bination with sand and mud) that we recommend brake pads that have sinteredlinings. However, take notice of the fact that brake pads with sintered linings havenot been type-coded! Besides, they may cause greater wear on the brake discs.

BRAKE FLUID RESERVOIRS:The brake fluid reservoirs on front and rear wheel brakes have been designed insuch a way that even if the brake pads are worn it is not necessary to top up thebrake fluid. If the brake fluid level drops below the minimum level either thebrake system has a leak or the brake pads are completely worn.In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:KTM fills the brake systems with CASTROL DOT 5.1 brake fluid, one of the bestbrake fluids that is currently available. We recommend that you continue to use it.DOT 5.1 brake fluid is based on glycol ether and of an amber color. If you do nothave any DOT 5.1 for refilling, you may use DOT 4 brake fluid. However, youshould replace it as soon as possible by DOT 5.1.

Adjusting of free travel at the hand brake leverFree travel at the hand brake lever may be readjusted by using adjustment screw1. In this way, the position of the point of pressure (i.e., the resistance you feelon the hand brake lever when the brake pads are pressed against the brake disc)can be adjusted for any hand size.

! CAUTION !AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM. ONLY THEN MAY THE

PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY THE GREATER RESI-STANCE OF THE HAND BRAKE LEVER). IF THIS FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL

BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE MAY FAIL DUE TO

OVERHEATING.

15 KG

max. 272 mm

1 2 3 16 17 18

DOT5.1

DOT5

✓ ✕

1

min. 3 mm

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Checking of brake fluid level - front brakeThe brake fluid reservoir is linked with the hand brake cylinder at the handlebarand the reservoir is provided with an inspection glass. With the reservoir in a hori-zontal position, the brake fluid level should not drop below the middle of the glass.The reservoir should be kept completely full at all times for best performance.

� WARNING �IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir*When the brake fluid falls to the middle of the inspection glass, new brake fluidhas to be added.Loosen screws 2 and remove lid 3 and membrane 4. Place hand brake cylinder in a horizontal position and fill the brake fluid reservoirto 5 mm (0,2 in) below the rim with clean brake fluid DOT 5.1 (Shell AdvanceBrake DOT 5.1). Replace membrane and lid, tighten screws. Rinse off spilled oroverflowing brake fluid with water.

� WARNING �– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR.

SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR.

! CAUTION !– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER.– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the front brake padsThe brake pads can be inspected from below. The linings nust be at least 1 mm(0,04 in) thick.

� WARNING �AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF

HAVING YOUR BRAKE PADS CHANGED.

! CAUTION !IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing front brake pads*Press the brake caliper toward the brake disk, to put the brake piston in its basicposition. Remove clips 1 and pull out bolt 2. Remove brake pads from the brakecaliper. Clean the brake caliper and the brake caliper support with compressed air.Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary.

min.1 mm

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Mount the right brake pad and fix it with the bolt. Mount the left brake pad andinsert the bolt until it stops. Mount the clips.When mounting the brake pads, be sure to check for correct fit of the slidingmetal-sheet 3 in the caliper support and of the leaf spring 4.

� WARNING �– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.– HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALLWAYS ACTUATE

THE HAND BRAKE LEVER OR FOOT BRAKE LEVER, RESPECTIVELY SO AS TO ENSURE THAT THE

BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED.

Changing the basic position of the brake pedal*The basic setting of the foot brake pedal can be changed by turning the end stoproller 5. Using the push rod 6, the free play on the foot brake pedal must be set.Measured on the outside, the foot brake pedal must have 3-5 mm of free play,before the push rod can move the piston in the brake cylinder (to be recognisedfrom the resistance on the foot brake pedal).

! CAUTION !IF THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND THE

BRAKE PADS BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY

IN EXTREME CASES.

Check the rear brake fluid level The reservoir for the rear disc brake is locaded above the main brake cylinder. Thelevel of brake fluid may not fall below the „MIN” mark when the vehicle has beenleft standing upright

� WARNING �IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir*When the brake fluid level has dropped to the MIN mark, you need to refill thebrake fluid reservoir. This is done by first unscrewing the cap 7 and rubber bel-lows 8. Add brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1) until it reachesthe MAX mark, then screw rubber bellows and cap back on. Rinse off spilled oroverflowing brake fluid with water.

� WARNING �– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR

! CAUTION !– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER.– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

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Checking the rear brake padsThe brake pads can be inspected from the rear. The thickness of the linings maynot be less than 1 mm (0.04 in).

� WARNING �AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF

HAVING YOUR BRAKE PADS CHANGED.

! CAUTION !IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing the rear brake pads*Press brake caliper 1 in direction of chain wheel for the brake piston to reach itsbasic position. Remove safety device 2, knock out the guide pin 3 from thebrake caliper with a drift towards the chain wheel and remove brake pads.Carefully clean the brake caliper with compressed air and check sleeves of theguide pins for damage.Slide left brake pad into the brake caliper and fix it with the pin. Slide in the rightbrake pad and knock the bolt in as far as it will go. Mount safety device 2.

� WARNING �– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.– HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALLWAYS ACTUATE

THE HAND BRAKE LEVER OR FOOT BRAKE LEVER, RESPECTIVELY SO AS TO ENSURE THAT THE

BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED.

Dismounting and mounting the front wheel (SX, SC)– To remove the front wheel, jack the motorcycle up on its frame so that the

front wheel no longer touches the ground.– Loosen the collar screw 4 and unscrew it approx. 5 turns.– Loosen the 4 clamping screws 5 on the fork leg axle passage.– Use the collar screw to push the wheel spindle forward and remove the collar

screw.– Hold the front wheel, pull out the wheel spindle 6

NOTICE: the wheel spindle may be pulled out more easily, if you slide anopen-end wrench (17mm) onto the flat portion of the wheel spindle.

– Remove front wheel carefully from the fork and take the speedometer drive 7off the hub.

! CAUTION !DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED.

– Prior to mounting the front wheel, clean and grease sealing ring 8 and run-ning surface 9 at the speedometer drive.

– To mount the front wheel, lift it into the fork. Insert speedometer drive intothe hub. Make sure that the driving tabs bk engage with the slots of the drive.

– Position front wheel and speedometer drive, and mount wheel spindle.– Mount collar screw 4, turn speedometer drive in a way that the flexible spee-

dometer shaft will curve upwards in a slight bow and tighten collar screw to40 Nm (30 ft.lb).

– Take the motorcycle off the stand and bounce the fork hard a few times toalign the fork legs

– Then tighten clamping screws 5 to a max. torque of 10 Nm (7 ft.lbs)

� WARNING �– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE

THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. ALOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS.– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

min.1 mm

1

23

45 56

78

9 10

180 mm

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23

Dismounting and mounting the front wheel (EGS)To remove the front wheel, jack the motorcycle up by the frame so that the frontwheel no longer touches the ground. Loosen the collar screw 1, and the 4 clam-ping screws 2 on the axle clamps. Screw off the speedo-meter drive cable fromspeedometer drive. Hold the front wheel, pull out the axle 3 remove front wheelcarefully from the fork and take speedometer drive 4 off the hub.

! CAUTION !DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN MOUNTED.

Prior to mounting the front wheel, clean and grease seal 5 and running surface6 at the speedometer drive.When mounting the front wheel, insert speedometer drive into the hub, andintroduce brake disk into brake caliper. Let tongue 7 of the retaining metal sheetbe in contact with the flat area of the axle clamp and mount axle without forcingit on. Fasten speedometer drive cable. Mount the collar screw and tighten with40 Nm (30 ft.lbs). Take the motorcycle off the stand and bounce the fork hard afew times to align the fork spars. Then screw clamping screws 2 tight to 7 Nm (5 ft.lbs).

� WARNING �– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE

THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. ALOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS.– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

Dismounting and mounting the rear wheel*Jack the motorcycle up on its frame so that the rear wheel no longer touches theground. Loosen the collar nut 8, hold the rear wheel and pull out the wheelspindle 9 until the rear wheel is free but the brake caliper support is still held.Push the rear wheel as far forward as possible, take the chain from the chainwheel and carefully take the rear wheel out of the swingarm.

! CAUTION !– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR

NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM

JAMMING.

The rear wheel is remounted in reverse order. Before tightening the collar nut to80 Nm (59 ft.lb), push the rear wheel forwards so that the chain tensioners lie onthe tension screws.

� WARNING �– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE

THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. ALOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE PRES-SURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

1

2

2

3 4

5

67

8

9

9

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24

Check the cush-drive rubbers rubbers in the rear wheel hub (EGS)*Some of the LC4 models have a cush-drive rear wheel hub. In this case, theengine power is conveyed from the rear sprocket via 6 cush-drive rubbers 1 tothe rear wheel. These 6 cush-drive rubbers wear with increased operation time,and should be checked for wear whenever the rear wheel is dismounted.

For this purpose, lie the rear wheel on a work bench with the sprocket facingupwards, and place the sprocket carrier into the hub. Now hold the rear wheelfirmly and try to turn the sprocket. The sprocket may not turn more than a maxi-mum of 5 mm (0,2 in) measured from the outside edge of sprocket. If freeplay inthe sprocket is greater, all 6 cush-drive rubbers are to be replaced.Check the cush-drive rubbers for signs of damage and contamination.

! CAUTION !IF THE CUSH-DRIVE RUBBERS ARE NOT REPLACED IN GOOD TIME, THE SPROCKET CARRIER

AND THE REAR WHEEL HUB WILL BE DAMAGED. ONLY REPLACE ALL 6 CUSH-DRIVE RUBBERS,NEVER SINGLE RUBBERS.

Tires, air pressureTire type, tire condition, and air pressure level affect the way your motorcyclerides, and they must therefore be checked whenever you are getting ready to goanywhere on your motorcycle.– Tire size can be found in the technical specifications and in their homologation

certificate– Tire condition has to be checked every time you want to ride your motorcycle.

Before leaving, check tires for punctures and nails or other sharp objects thatmight have become embedded in them.Refer to the specific regulations in your country for minimum tire tread requi-rements. We recommend you replace the tires at the latest when the tread isdown to 2 mm.

– Tire pressure should be checked regularly on a “cold” tire. Proper pressureensures optimum driving comfort and extends the life of your tires.

� WARNING �– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES

COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.– FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD

LAYOUT. USE HOMOLOGATED TIRES

– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.– WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS,

ESPECIALLY ON WET SURFACES

– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN

RESULT

front rear

Off road 1,0 bar (14 psi) 1,2 bar (17psi)

Road driver only 1,5 bar (21 psi) 2,0 bar (28 psi)

Road w. passenger 2,0 bar (28 psi) 2,2 bar (31 psi)

TIRES - AIR PRESSURE

1

1

max 5 mm

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25

Checking spoke tensionThe correct spoke tension is very important for the stability of the wheels and thusfor riding safety. A loose spoke causes the wheel to become unbalanced andbefore long other spokes will have come loose. Check spoke tension, especially ona new motorcycle, in regular intervals. For checking, tap on each spoke with theblade of a screwdriver (see photo). A clear tone must be the result. Dull tones areindicators of loose spokes. If necessary, have the spokes retightened and the wheelcentered by a KTM dealer.

� WARNING �SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN UNSTA-BLE HANDLING OF YOUR MOTORCYCLE.

Battery (A, CH)The battery 1 is mounted under the seat (remove the seat, see page 15). It is ahigh-quality, maintenance-free unit.In order to avoid an oxidation at the connections, lubricate the battery terminalswith non-corrosive grease regularly.Never open up the valves!

STORAGE:Keep battery dry and clean. Charge battery, before storage. Best storage tempera-ture is 0-35°C (31°F - 94°F). At 20°C (67°F) storage temperature the battery is tobe recharged after 16 months at the latest. A discharged battery must be rechar-ged after one week at the latest.CHARGE:– nominal voltage: 12 volts– maximum charging current: 0.3 amperes,

recommended charging current: 0.2 amperes– charging time depending on degree of discharge: 4-6 hours

Fuse parking light (A, CH)One can find the fuse 2 near the battery, under the seat. Only the parking light isprotected by this fuse. All the other electrical components are powered directly bythe generator when the engine is running.Replace blown fuse only with equivalent one. If a new fuse that has just been setin, blows again, contact a KTM-dealer as soon as possible.

! CAUTION !UNDER NO CIRCUMSTANCES IS A FUSE ALLOWED TO BE SET IN OR “REPAIRED”. AN IMPRO-PER TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL SYSTEM!

Fuse fan (EGS)The fuse 3 for the fan is located behind the right radiator. With its 5 amps it isonly responsible for protecting the fan circuit. The fuse can be reached frombelow.Replace a blown fuse only with an equivalent one. If a new fuse that has just beenset in gets blown again, you are strongly advised to have it inspected by a KTMdealer.

! CAUTION !UNDER NO CIRCUMSTANCES IS A FUSE ALLOWED TO BE SET IN OR “REPAIRED”. AN IMPRO-PER TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL SYSTEM!

1

2

3

EN

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26

Replacing the headlight bulb (EGS)Remove the screws 1 from the left and right side and pull the headlight straightout of the headlight mask. Remove the screws 2 from the left and right side andtake out the headlight unit.

To change the headlight bulb, pull the plug from the bulb, turn the retaining clip3 counter clockwise, remove the bulb and dispose of the old bulb. Install thenew bulb by aligning the light bulb pins A with the socket groove B. Attach theretaining clip and plug. Start the motorcycle and check the headlight for properoperation.Slide the headlight unit into the housing without using force and install the screws 2. Mount the headlight.

Replacing the parking-light bulb (EGS)Disassemble the headlight as described above and simply pull the bulb socket 4out of the reflector.

Cooling system (SX, SC)Coolant is circulated by a water pump located in the engine. When the engine iscold the coolant circulates only through the cylinder and the cylinder head. Afterthe engine has reached its operating temperature (about 70°C, 158°F), the ther-mostat opens and the coolant is also pumped through both aluminum radiators.Air blowing in through the radiators cools the coolant. The slower the speed ofthe motorcycle, the less the coolant is cooled down. Dirty radiators also reducethe cooling efficiency.For the models listed above no fan is mounted in order to save weight.If little or no air passes through the radiators because traffic in the city slows youdown or you have to wait at a red light, the temperature of the cooling liquid canincrease to such an extent that the red cooling liquid temperature warning lamp5 will light up (110°). In this case, it is recommended to drive on with normalspeed as the warning light usually goes out soon after the radiators are once againexposed to a sufficiently strong flow of air. Do not forget to check the coolingliquid level later after the engine has cooled down.

! CAUTION !IF THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP EVEN THOUGH YOU

ARE DRIVING ALONG BRISKLY, IT IS MOST LIKELY THAT THERE IS A DEFECT IN THE COOLING

SYSTEM. IN THIS CASE, STOP IMMEDIATELY, SINCE OTHERWISE YOU MAY DAMAGE YOUR

ENGINE. LET YOUR ENGINE COOL DOWN, CHECK THE COOLING SYSTEM FOR LEAKS, AND

CHECK THE COOLANT LEVEL. CAUTION - SCALDING HAZARD! DO NOT DRIVE ON,UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM.

� WARNING �IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT, USE A RAG TO COVER THE

CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

12

3

4

A

B

5

EN

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27

� WARNING �IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP 6 WHEN THE ENGINE IS HOT, USE A RAG TO COVER THE

CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

A mixture of 40% anti freeze liquid and 60% water is used as coolant. However,the anti-freeze protection must be at least -25° C (-13° F). This mixture offers anti-freeze protection but also good corrosion protection and should therefore not bereplaced by pure water.

! CAUTION !FOR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (SHELL ADVANCE

COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND COO-LANT FOAMING.

Pressure induced by heating of the coolant in the system is controlled by a valvein the radiator cap 6; a water temperature rising up to 120° C (248° F) is admis-sible, without fear of problems.

Cooling system (EGS)Coolant is circulated by a water pump located in the engine. When the engine iscold the coolant circulates only through the cylinder and the cylinder head. After theengine has reached its operating temperature (about 70°C, 158°F), the thermostat7 opens and the coolant is also pumped through both aluminum radiators.Air blowing in through the radiators cools the coolant. The slower the speed ofthe motorcycle, the less the coolant is cooled down. Dirty radiators also reducethe cooling efficiency.If little or no air blows through the radiators, for example when riding throughslow traffic or waiting at traffic lights, the coolant temperature will rise. If the coo-lant temperature rises to 85° C ((185°F), the fan 9 on the left radiator will switchon. This fan will provide additional air circulation through the radiator therebypreventing the cooling system from overheating.

! CAUTION !IF THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP, THIS WILL MOST

LIKELY BE DUE TO A DEFECT IN THE COOLING SYSTEM. IN THIS CASE, STOP IMMEDIATELY

AND TURN OFF THE ENGINE. LET THE ENGINE COOL DOWN AND CHECK THE COOLING

SYSTEM FOR LEAKS. ALSO CHECK IF THERE IS ENOUGH COOLING LIQUID. CAUTION -SCALDING HAZARD! 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 YOU DRIVE ON EVEN THOUGH THE COOLING

LIQUID TEMPERATURE WARNING LAMP IS LIT, YOU WILL DAMAGE YOUR ENGINE.

� WARNING �IF THE RADIATOR CAP IS REMOVED WHEN THE ENGINE IS HOT, HOT COOLANT, THAT IS

UNDER PRESSURE, CAN SPRAY OUT AND CAUSE SEVERE BURNS.

A mixture of 40% anti freeze liquid and 60% water is used as coolant. How-ever,the anti-freeze protection must be at least -25° C (-13° F). This mixture offers anti-freeze protection but also good corrosion protection and should therefore not bereplaced by pure water.

! CAUTION !FOR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (SHELL ADVANCE

COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND COO-LANT FOAMING.

Pressure induced by heating of the coolant in the system is controlled by a valvein the radiator cap bk; a water temperature rising up to 120° C (248° F) is admis-sible, without fear of problems.

6

7

8

9

10

EN

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28

Checking the coolant levelThe coolant should be 10 mm (0,4 in) above the radiator fins when the engine iscold (see illustr.). In the event of the coolant being drained, always fill and bleedthe system.

� WARNING �IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT, USE A RAG TO COVER THE

CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

Cleaning of air filter*To do this, remove the seat and the air filter cover from the air filter box. Unclapthe filter holder 1, swing back and remove air filter plus filter carrier from the fil-ter box.

! CAUTION !DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE FOAM.KTM RECOMMENDS THE PRODUCTS OF THE COMPANY PUTOLINE FOR AIR FILTER MAIN-TENANCE. „ACTION CLEANER“ FOR CLEANING PURPOSES AND „ACTION FLUID“ TO OIL THE

FOAM FILTER.Thoroughly wash the foam filter in special cleaning fluid and allow to dry well.Only press out the filter, do not wring out under any circumstances. Oil the dryfoam filter with a high grade filter oil. Also clean the air filter box. Check carburet-tor collar for damage and that it is fitted correctly.

Mount the air filter on the filter support 2. Grease the front side A of the filter,to improve the seal. Mount the air filter and the filter support in the filter box.Make sure they are centered B, and lock into place with the filter holder 1.

Exhaust system *Aluminium silencers are filled with glass fiber yarn. If exposed to heat for longerperiods of time, however, the glass fiber yarn pack will come unravelled, whichcan reduce both overall performance and the performance of the silencer. Experi-ence has shown that the front glass fiber pack 3 must be replaced more oftenthan the rear pack 4.To replace the front glass fiber yarn pack, remove the silencer. Remove the frontcap 5, pull the front glass fiber yarn pack out of the silencer, mount a new packon the internal exhaust pipe, insert the internal exhaust pipe into the silencer andreplace the cap. To replace the rear glass fiber yarn pack, drill the rivets open and remove the rearcap 6.Always renew the O-rings 7.Glass fiber yarn packs are available in your KTM store.

� WARNING �THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING. TO AVOID

BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED

DOWN.

when engine is cold

10 mm

1

2

A

B

1

34

57

7

6

EN

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29

CARBURETOR – Adjust idling (DellOrto)*Idling adjustment of the carburetor strongly affects the engine’s starting behavior.That is, an engine whose idling speed is adjusted correctly will be easier to startthan one whose idling speed has not been adjusted correctly.Idling is controlled by the throttle stop screw 1 and the mixture control screw2. The throttle stop screw is used to adjust the basic position of the throttle. Themixture control screw is used to control the idle mixture which arrives at theengine via the idle system. Turning it clockwise will reduce the amount of gaso-line (lean mixture), turning it counterclockwise will increase the amount of gaso-line (rich mixture).TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:1 Turn in mixture control screw 2 up to the stop, and turn it back out by 1.5

turns2 Warm up the engine3 Use throttle stop screw 1 to adjust normal idling speed (1400-1500 r.p.m.)4 Turn mixture control screw 2 slowly clockwise until idling speed starts to

decrease. Memorize this position, and turn mixture control screw slowly coun-terclockwise until the idling speed will decrease again. Adjust the point of thehighest idling speed between these two positions. (The highly competitive userwill make his adjustment 1/4 turn leaner because his engine will heat up morein competitive use).NOTE: If you fail to obtain a satisfying result by following the procedure descri-bed above, an incorrectly dimensioned idling nozzle may be the cause. In case:a) the mixture control screw has been screwed in up to the stop without cau-sing any change in rotational speed, a smaller idling jet has to be installed;b) the engine dies when the mixture control screw is still open by 2 turns, alarger idling jet needs to be selected;Naturally, in cases of jet changes, you have to start your adjusting work fromthe beginning.

5 Now, use the slide stop screw to adjust the desired idling speed6 In cases of greater changes in outside temperature and extremely different alti-

tudes, the idling speed should be readjusted.

Basic information on carburetor wearAs a result of engine vibrations, throttle valve, jet needle, and needle jet are sub-jected to increased wear. This wear may cause carburetor malfunction (e.g.,overly rich mixture). Therefore, these parts should be replaced after 10000 kilo-meters (6000 miles).

Adjust hot start device (DellOrto)*If the hot start button was removed when cleaning the carburetor, re-adjust thehot start device.Install carburetor and adjust idling as discribed above. Then unlock nut 3, pressin hot start device 4 and adjust engine rev with adjusting screw 5 to 2000-2500rpm. Tighten locking nut.

Check float level (DellOrto)*Stand the carburettor diagonally at about 60° so that the spring in the float needlevalve is not pressed together. In this position, the edge of the float should be paral-lel with the float bowl sealing surface (see illustration).

Checking axial play of float (DellOrto)*For proper functioning of the float, there must be an axial play of 0.8 mm (0,03in). If necessary, slightly abrade and deburr lateral float guide.

1 2

60°

0,8 mm

3

4

5

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Adjusting the throttle cable (SX, SC)*There must always be 3-5 mm play in the throttle cable. To check this, move backthe protective cover 1 on the twist grip. It must be possible to lift the outercovering of the cable 3-5 mm (0,12-0,20 in) from the counterbearing of the twistgrip, until resistance is felt.

To adjust, remove the seat and the gastank, push the protective cover upwards,loosen the counter nut and turn the adjustment screw 2 accordingly. Turn theadjustment screw clockwise for more play or counterclockwise for less play.Tighten the counter nut, replace the protective covers and mount the gas-tankand the seat.

Adjusting the throttle cable (EGS)*There must always be a 3-5 mm (0,12-0,20 in) play in the throttle cable. To checkthis, move back the protective cover 3 on the twist grip. You must be able to liftthe outer covering of the cable 3-5 mm from the adjustment screw 4, until resi-stance is felt.To adjust, loosen the counter nut 5 and turn the adjustment screw accordingly.Finally tighten counter nut and push back protective cover.

Adjusting the choke cable (SX, SC)*The choke cable must have a play of approximately 2 mm at all times. To checkthe play turn the knob 6 into the initial position. Now it should be possible to liftthe exterior case of the choke cable approximately 2 mm from the supporting sur-face of the choke knob before the upward movement is blocked by resistance.

To adjust, remove the seat and the gastank, push the protective cover upwards,loosen the counter nut and turn the adjustment screw 7 accordingly. Turn theadjustment screw clockwise for more play or anticlockwise for less play.Tighten the counter nut, replace the protective cover and mount the gas-tank andthe seat.

3-5 mm 1

2

3-5 mm

2 mm

45 3

6

7

EN

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31

Adjusting the choke cable (EGS)*At the choke cable, there must always exist a play of approx. 2 mm. To checkthis, push choke lever fully forward and pull protective cover 1 from the adjusterpiece 2. Now, it must be possible to lift the outer covering of the cable byapprox. 2 mm from the adjuster piece until feeling a resistance. If necessary, loo-sen lock nut and correct play by turning the adjuster piece. Tighten lock nut, andslide on protective cover.

Adjusting the clutch cableWhen the engine is cold, the play at the clutch lever should be 1-3 mm(0,04–0,12 in) (measured at the outer edge).To adjust the clutch cable turn the adjustment nut 3 accordingly.

Checking the adjustment of the hand decompressionrelease cable*To check, set piston at compression, so that the valves are closed. While doingthis, slowly kick the kick starter through its stroke until the clicking sound (disen-gaging) of the automatic decompression release can be heard. Now the deko-levermust be operated 25 mm (1 in) until resistance is felt (the exhaust valves begin toopen). To adjust move back the protective cover 4, loosen the counter nut 5and correct the adjustment screw 6 accordingly. Tighten counter nut and pushback protective cover.

! CAUTION !IF THERE IS NO PLAY IN THE DEKO-LEVER, THIS CAN RESULT IN ENGINE DAMAGE.

NOTE:No adjustment need be made to the automatic decompressor.

Engine oilOnly use high-quality oils (Shell Advance Ultra 4) meeting or surpassing the qua-lity requirements of API classes SF, SG, or SH (for specifications see containers).You may use either mineral oils or synthetic oils fulfilling the above criteria.

! CAUTION !INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE.

2 mm

12

1–3 mm

3

4

56

25 mm

� �– +0°C32°F

15W 4015W 5015W 60

10W 4010W 5010W 60

API: SF, SG, SHTEMPERATUR

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Checking engine oil levelAllow the engine to run at idle for about 4 minutes. Turn off the engine and placethe motorcycle on a flat, level surface (main stand). Take out the oil dipstick andwipe it off with a cloth. SCREW THE OIL DIPSTICK COMPLETELY INTO THE FILLER HOLE AND THENREMOVE IT. The oil level should be within the flat area of the oil dipstick. Addoil if necessary.

! CAUTION !– INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE.– CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE REA-

DING IN THE OIL DIPSTICK ANT THERERORE AN INCORRECT OIL LEVEL. – DO NOT OVERFILL THE CRANKCASE.– DO NOT UNDERFILL THE CRANKCASE.Check the engine for leaks.

Oil circuit (SX, SC)The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil fil-ter 3. After the oil filter, an oil lead branches off to a jet 4 which sprays engineoil onto the piston pin bearing and piston head. The second oil lead takes themain flow of oil to the microfilter 5, which filters out even the finest impurities.The cleaned engine oil is pumped through the oil lead and the clutch cover intothe crankshaft to the connecting rod bearing 6 and drips into the crankcase. Anadditional oil pump 7 sucks the engine oil out of the crankcase and pumps itthrough the oil line 8 to the gear wheels of the 4th and 5th gear. Via the gearwheels, the engine oil reaches the oil sump. The timing chain 9 runs through theoil sump and transports the engine oil upwards to the cylinder head. Through thebore bk the oil reaches the camshaft bl and the valves.

MAX

MIN

87

1

2

3

4

5

6

9

10 11

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Changing the engine oil (SX, SC)*The engine oil change is to be carried out when the engine is still warm.

� WARNING �AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT - DO NOT

BURN YOURSELF.Place the motorbike on a horizontal surface. Remove the two plugs (1 and 2),and drain oil into a container.

! CAUTION !THE SCREW PLUG A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. Clean the plugs thoroughly with a fireproof solvent and compressed air, in orderto remove the metal abrasion. After all the oil has drained through, clean raisedand flat faces and install plugs with seals. Tighten plug 1 with 30 Nm (22ft.lb)and plug 2 with 20 Nm (15ft.lb).Remove oil dipstick on the clutch cover and fill with 1.5 litre engine oil (ShellAdvance Ultra 4). Warm up engine, check engine oil level and refill up to the marking MAX. Finallycheck the oil system for leaks.

Changing and bleeding the microfilter (SX, SC)*Replace the microfilter while changing the engine oil. To do so, remove hexagonscrews 3 and take off the microfilter cover 4. Remove the microfilter, clean itsparts and check the O-ring on the microfilter lid for signs of damage. Beforeinstalling the new micro filter, soak it in clean engine oil. Place a new microfilterin the filter housing, apply a thin layer of grease to the O-ring and mount themicrofilter cover. It is necessary to bleed the micro filter so that all friction areas can be quickly sup-plied with engine oil. To do this, fill with oil and remove the jet screw 6 from theoil line on the clutch cover. Start the engine and close off the oil filler hole on theclutch cover with a rag. Allow the engine to run at idle until oil runs out of the oilline 5. Turn the engine off. Install seal rings and the jet screw. Torque the jetscrew to 10 Nm and check for leaks.

Oil circuit (EGS)The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil fil-ter 3. After the oil filter, an oil lead branches off to a jet 4 which sprays engineoil onto the piston pin bearing and piston head. The second oil lead takes themain flow of oil into the front pipe of the frame 5, where the engine oil is cooleddown. Afterwards the engine oil runs through the fine screen filter 6, which fil-ters out even the finest impurities. The cleaned engine oil is pumped through theoil lead and the clutch cover into the crankshaft to the connecting rod bearing 7and drips into the crankcase. An additional oil pump 8 sucks the engine oil out ofthe crankcase and pumps it through the oil line 9 to the gear wheels of the 4thand 5th gear. Via the gear wheels, the engine oil reaches the oil sump. The timingchain bk runs through the oil sump and transports the engine oil upwards to thecylinder head. Through the bore bl the oil reaches the camshaft bm and the valves.

1

2

A

3

4

5

6

8

7

1

23

4

5

6

9

10

1211

EN

GLIS

H

34

Oil change and bleeding of the oil system (EGS)*NOTE: For improved cooling of the engine oil the front pipe of the frame is inter-grated into the oil circuit. When changing the oil, the engine oil has also to bedrained from the front pipe.The engine oil change is to be carried out when the engine is still warm.

� WARNING �AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT - DO NOT

BURN YOURSELF.

Place the motorcycle on a horizontal surface. Remove the two plugs (1 and 2),and drain oil into a container. Remove cover, unscrew plug 3 at the lower end ofthe frame tube and drain oil.

! CAUTION !THE PLUG A NEXT TO THE TOP OF THE CRANKCASE MUST NOT BE REMOVED, THIS IS PART

OF THE BY-PASS VALVE.Clean all 3 plugs thoroughly with a fireproof solvent and compressed air, in orderto remove the metal abrasion. After all the oil has drained through, clean raisedand flat faces and install plugs with seals. Tighten plug 1 with 30 Nm (22 ft.lb)and plug 2 and 3 with 20 Nm (15 lb.ft).

Remove oil dipstick on the clutch cover, fill with 2,0 litre engine oil (ShellAdvance Ultra 4) and attach plug again.

! CAUTION !IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRAME TUBE, YOU MUST BLEED THEOIL SYSTEM !To allow the air to escape from the frame tube, remove plug 4 next to the stee-ring head. Start engine and let it run in idle (1-2 minutes) until oil escapes at thebore B. As soon as oil starts to escape, turn off the engine, and mount plugtogether with the seal.

! CAUTION !DO NOT REV UP THE ENGINE DURING THE BLEEDING PROCEDURE BECAUSE NOT ALL THE

LUBRICATING POINTS WILL ALREADY HAVE BEEN SUPPLIED WITH SUFFICIENT AMOUNTS OF OIL.

Warm up engine, check engine oil level and refill up to the marking MAX. Finally,check the oil system for leaks.

NOTE: Dispose of used oil properly! Under no circumstances may used oil be dis-posed of in the sewage system or in the open countrysize. 1 liter used oil contami-nates 1.000.000 liters water.

Changing the fine screen filter (EGS)*Replace the fine screen filter when changing the engine oil. To do so, loosen thethree screws and remove the cover 5. Loosen the fine screen filter with an oil fil-ter wrench; you will be able to unscrew it the rest of the way with your barehand. Let engine oil flow out of the main frame tube.

Clean sealing surfaces on the frame tube 6, fill new fine screen filter with engineoil, and oil rubber seal 7. Replace fine screen filter and screw it back in place,your bare hand will do. Start motor, bleed oil system (see Changing the EngineOil) and make sure fine screen filter does not leak.

! CAUTION !– USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. USING ANOTHER FILTER BRAND CAN

RESULT IN DAMAGE TO THE ENGINE.– IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRAME TUBE, YOU MUST BLEED

THE OIL SYSTEM !

6

7

5

1

2

A

3

4

B

EN

GLIS

H

35

Changing oil filter *Replace the oil filter when changing the engine oil. Press the foot brake lever andplace a screwdriver or similar between foot brake lever and stopper roll so that theoil filter cover is more accessible. Remove banjo bolt 1 and the three allen headscrews. Remove oil filter cover 2 and oil filter. Clean filter case, oil filter cover,and sealing surfaces. Check oil chanel in oil filter cover if clogged.

The O-ring 3 need not be replaced unless it is damaged. Press the O-ring into thegroove of the oil filter cover, mount a new oil filter 4 on the oil filter cap andmount the unit. Insert the 3 screws and tighten them with 5 Nm (4 ft.lb). Mountthe banjo bolt with the gaskets and tighten it with 15 Nm (11 ft.lb).Then start the engine and check the oil system for leaks.

1

2

1

2

3

4

EN

GLIS

H

36

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevert-heless, we advise you to use the trouble shooting chart in order to find the cause of error.We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.

TROUBLE

Engine will not start

Engine will not idle

Engine does not rev high

CAUSE

Operating error

Fuel supply interrupted

Flooded engine

Sooty or wet spark plug

Electrode gap too large

Spark plug connector or spark plugfaulty

If connector oxidates from generator toignition coil

Short circuit cable scored in wiringharness, ignition lock, emergency OFFswitch or short circuit button faulty

Water in short emergency OFF switch

Water in carburettor or jets blocked

Carburettor does not fit in properly atintake flange

Idling jet blocked

Adjusting screws on carburettor uncor-rect adjusted

Ignition system faulty

Carburettor fuel level too high becausefloat needle valve is dirty or worn out

Loose carburettor jets

Electronical ignition timing faulty

REMEDY

Switch on ignition, switch on emergency OFF switch, open fuel tap,tank fuel, do not use choke i.e. the hotstart device. Pay attention tostarting off information (see driving instructions).

Close fuel tap, loosen fuel hose at carburettor, lead into a basin andopen fuel tap,– if fuel leaks out, clean carburettor– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

See driving instructions

Clean or replace spark plug

Adjust spark plug elektrode gap to 0,6 mm

Dismount spark plug, connect ignition cable, hold to ground (blankplace on engine) and actuate kickstarter, a strong spark must be pro-duced at the spark plug– If no spark is produced, loosen spark plug cap from ignition cable,

hold about 5 mm from ground and actuate kickstarter– If a spark now occurs, replace spark plug cap– If no spark is produced, control ignition system

Remove fuel tank, clean connector and treat with contact spray

Remove fuel tank, draw off blue/black cable from orange cable ofignition coil and check spark.– If a spark is produced, seek fault in short circuit current

Remove 2-pole connector located underneath the headlight mask,treat emergency OFF switch with contact spray

Dismount and clean carburettor

Check if carburettor is fitted in correctly

Dismount carburettor and clean jets

Adjust carburettor

Have ignition system checked

Dismount carburettor and check if worn out

Tighten jets

Have ignition system checked

TROUBLE SHOOTING

EN

GLIS

H

37

TROUBLE

Engine will not reach fullpower

Engine stops or splutters in car-burettor

Engine gets to hot, cooling liquid tmperature war-ning lamp lights up

High oil consumption

All switched on lamps blownout

Parking light does not shine(only models with battery)

CAUSE

Fuel supply partically interrupted orcarburettor dirty

float is not tight, or no axial play

Air filter very dirty

Exhaust leaking or blocked

Valve gap to small

Loss of compression because handdecompressor has no play

Electronical ignition timing faulty

Insuffient fuel

Engine takes air out of control

Insufficient cooling liquid

Not enough air stream (SX, SC)

Defect of cooling fan, fuse of coolingfan, or thermostatic switch (EGS)

Radiators very dirty

Foam formation in cooling system

Bent cooling hose

Thermostat defective

Buckling gearing ventilation hose

Engine oil level too high

Motor oil too thin (viscosity)

Capacitor or voltage regulator faulty

Fuse melted

REMEDY

Clean and check fuel system as well as carburettor

replace or abrade the float

Clean or replace air filter

Check if exhaust is damaged, replace glas fibre yarn in exhaustsilencer

Adjust valve gap

Check setting of the hand decompression cable

Have ignition system checked

Clean and check fuel system and carburettor

Check intake flange and carburettor if firmly setted

Refill cooling liquid (see maintenace work), check cooling systemfor leaks

Drive on briskly

Check fuse, bypass thermostatic switch, check coolant level

Clean radiators with water jet

Replace cooling liquid, use anti freeze liquid with brand name

Shorten or replace cooling hose

Dismount and check thermostat (opening temperature 70°C,158°F) or replace it

Dislocate i.e. replace non-buckling vetilation hose

Check engine oil level when the engine is warm; correct if necessary

Use thicker engine oil; see chapter „Engine oil“

Remove right side cover and control connections. Have capacitorand voltage regulator checked

Remove seat and replace fuse

EN

GLIS

H

38

Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt canbe removed before washing with the help of a soft water jet.

! CAUTION !NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL

COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS.– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should be cleaned additionally with the help of a

paint brush.– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the

engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate frominaccessable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of the motorcy-cle is allowed to evaporate.

– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Treat the chain with a chain spray too.– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, the short circuit button, the light

switch and the socket connectors with contact spray.

Should you desire to make a pause over a longer space of time, please observe the following instructions:

– Clean motorcycle thoroughly (see chapter: CLEANING)– Change engine oil, oil filter and micro filter and fine screen filter (old engine oil contains aggresive contaminants).– Check antifreezer and amount of cooling liquid.– Let the engine warm up again, close fuel cock and wait until the engine dies off by itself. By this means, carburetor jets are prevented from

becoming resinous by the old fuel.– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in order to distri-

bute the oil onto the cylinder walls and mount the spark plug.– Set piston to compression so that the valves will be closed. While doing this, slowly kick the kick starter through its stroke until the clicking

sound (disengaging) of the automatic decompression release can be heard. – Let fuel flow out of tank into an appropriate container.– Correct tire pressure.– Lubricate bearing points of the control levers, foot rests, etc. as well as the chain.– Service the rear suspension linkage– Disassemble and charge battery (see chapter: BATTERY).

NOTE: Only the following models are equipped with a battery: EGS Austria, EGS Switzerland.– The storage place should be dry and not be subject to too big temperature fluctuations.– Cover the motorcycle with an air permeated tarp or blanket. Do not use non air permeable materials as a possible humidity might not be able to

escape and thereby cause corrosion.

! CAUTION !IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE

THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST.

RE-INITIATION AFTER TIME OF STORAGE– Mount the charged battery (regard polarity).– Fill up tank with fresh fuel.– Check motorcycle as before each start (see driving instructions)– Take a short, careful test ride first.

CLEANING

STORAGE

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautionsagainst the aggressive road salt.– clean motorcycle thoroughly and let it dry after each riding– treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion agent.

� WARNING �KEEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER.

! CAUTION !AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

CONSERVATION FOR WINTER OPERATION

EN

GLIS

H

39

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oil p

ump

M6

Loct

ite 2

42 +

8 N

m(6

ft.lb

)

Hex

agon

scr

ew c

amsh

aft g

ear

M10

35 N

m(2

6 ft.

lb)

AH

scr

ew c

ylin

der

head

top

sect

.M

6x25

8 N

m(6

ft.lb

)

AH

scr

ew c

ylin

der

head

top

sect

.M

6x50

/M6x

55 (1

2.9)

20 N

m(1

5 ft.

lb)

AH

scr

ew c

ylin

der

head

top

sect

.M

6x65

/M6x

70 (8

.8)

8 N

m(6

ft.lb

)

Cyl

inde

r he

ad s

crew

sM

1050

Nm

(37

ft.lb

)

Col

lar

nuts

at c

ylin

der

base

M10

40 N

m(3

0 ft.

lb)

Hex

agon

scr

ew c

hain

spr

ocke

tM

10Lo

ctite

242

+ 4

0 N

m(3

0 ft.

lb)

Oil

drai

n pl

ugM

22x1

,530

Nm

(22

ft.lb

)

Mag

netic

plu

gM

12x1

,520

Nm

(15

ft.lb

)

Plug

byp

ass

valv

eM

12x1

,520

Nm

(15

ft.lb

)

Banj

o bo

lts o

il lin

esM

8x1

10 N

m(7

ft.lb

)

Banj

o bo

lt oi

l lin

esM

10x1

15 N

m(1

1 ft.

lb)

Jet s

crew

clu

tch

cove

rM

8x1

10 N

m(7

ft.lb

)

Scre

w p

lug

timin

g-ch

ain

tens

ione

rM

12x1

,520

Nm

(15

ft.lb

)

Cou

nter

nuts

val

ve a

djus

ting

scre

ws

M7x

0,75

20 N

m(1

5 ft.

lb)

TIG

HT

ENIN

G T

OR

QU

ES -

ENG

INE

Cra

nk sh

aft

axia

l pla

y...

......

......

......

......

......

......

......

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- 0,

12 m

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05 in

)ru

n ou

t of c

rank

stud

......

......

......

......

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ax. 0

,04

mm

(0,0

016

in)

Conn

ectin

g ro

d be

arin

gra

dial

pla

y...

......

......

......

......

......

......

......

max

. 0,0

5 m

m(0

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9 in

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ial p

lay.

......

......

......

......

......

......

......

....m

ax. 1

,00

mm

(0,0

4 in

)

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onas

sem

bly

clea

ranc

e 40

0/62

0...

......

......

..max

. 0,1

2 m

m(0

,005

in)

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on ri

ngs e

nd g

apco

mpr

essio

n rin

gs...

......

......

......

......

......

.max

. 0,6

0 m

m(0

,023

in)

oil s

crap

er ri

ng...

......

......

......

......

......

......

max

. 0,8

0 m

m(0

,031

in)

Valv

es

seat

seal

ing

inta

ke...

......

......

......

......

......

.max

. 1,5

0 m

m0,

059

in)

seat

seal

ing

exha

ust.

......

......

......

......

......

max

. 2,0

0 m

m(0

,079

in)

run

out o

f val

ve h

eads

......

......

......

......

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ax. 0

,03

mm

(0,0

01 in

)va

lve

guid

es d

iam

eter

......

......

......

......

....m

ax. 7

,05

mm

(0,2

77 in

)

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pum

pcl

eara

nce

oute

r rot

or -

hous

ing.

......

......

..max

. 0,2

0 m

m(0

,008

in)

clea

ranc

e ou

ter r

otor

- in

ner r

otor

......

....m

ax. 0

,20

mm

(0,0

08 in

)

Bypa

ß va

lve

min

imum

sprin

g le

nght

......

......

......

......

......

......

.25

mm

(1 in

)

Clu

tch

disc

sw

ear l

imit

orga

nic.

......

......

......

......

......

......

......

.2,5

mm

(0,1

in)

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smiss

ion

shaf

tsax

ial p

lay

......

......

......

......

......

......

......

......

.0,1

- 0,

4 m

m(0

,004

in)

Clu

tch

min

imum

clu

tchs

prin

g le

nght

......

......

....3

4,5 m

m (ne

w 37

mm)

(1,36

in - n

ew 1,

45 in

)

TO

LER

AN

CE,

ASS

EMBL

Y C

LEA

RA

NC

E

EN

GLIS

H

41

Engi

ne o

ilU

se o

nly

oil b

rand

s, w

hich

mee

t qu

ality

req

uire

men

ts o

f A

PI-c

las-

ses

SF, S

G o

r SH

(inf

orm

atio

ns o

n bo

ttle

s) o

r hi

gher

. Bot

h, m

iner

alan

d sy

nthe

tic o

ils w

ith a

bove

spe

cific

atio

ns c

an b

e us

ed.

!C

AU

TIO

N!

POO

RO

ILQ

UA

LITY

OR

MIN

OR

QU

AN

TITY

EFFE

CT

EARL

YEN

GIN

E-W

EAR.

BASI

C C

AR

BUR

ETO

R S

ETT

ING

Car

bure

tor

Car

bure

tor

sett

ing

num

ber

Mai

n je

t

Nee

dle

jet

Idlin

g je

t

Jet n

eedl

e

Nee

dle

posi

tion

from

top

Mix

ture

.adj

u. s

crew

ope

n

Thro

ttle

val

ve

Star

ting

jet

Perf

orm

ance

res

tric

tor

PHM

38

SD

3008

96

150

DR

266

45 K 5

1

3 rd

1,5

turn

40 45

slid

e st

op 2

2 m

m

PHM

38

SD

4894

/6

190

DR

270

45 K 5

1

2 nd

1,5

turn

40 45 –

PHM

38

SD

3008

96

150

DR

266

45 K 5

1

3 rd

1,5

turn

40 45 –

PHM

40

SD

1109

96

155

DR

268

45 K 5

1

3 rd

1,5

turn

40 45

slid

e st

op 2

6 m

m

PHM

40

SD

4922

195

DR

272

45 K 5

1

2 nd

1,5

turn

40 45 –

PHM

40

SD

4922

/2

170

DR

268

45 K 5

1

3 rd

1,5

turn

40 45 –

PHM

40

SD

1109

96

155

DR

268

45 K 5

1

3 rd

1,5

turn

40 45 –

400

SC(2

0 kW

)40

0 SC

400

EGS

Cla

ssic

620

SC (

20 k

W)

620

SX62

0 SC

620

EGS

Cla

ssic

with

sec

unda

ry a

ir sy

stem

620

EGS

Cla

ssic

with

out s

ecun

dary

air

syst

em

� �

–+

0°C

32°F

15W

40

15W

50

15W

60

10W

40

10W

50

10W

60

API

: SF

, SG

, SH

TEM

PERA

TUR

#

K T M - S P O R T M O T O R C Y C L E A GA-5230 Mattighofen • Postfach 91 • AustriaI n t e r n e t : h t t p : / / w w w . k t m . c o . a tFN 102019 d - Landesgericht Ried im Innkreis