Starting when the engine is cold
7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the choke lever 3. Operate the starter tip switch 4 without accelerating. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Swing up the centerstand 9 Switch on the light before setting off. DO WARNING
NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
CAUTION ! MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. DONT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DONT REV ENGINE WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN MIND THAT THE ENGINE SHOULD BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M. !
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on. If this is not the case, the battery is discharged If the lights are on, proceed as described in the Trouble-shooting section or contact a KTM dealer. IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE STARTER TIP SWITCH: Check if the fuel tap is open Check if the choke lever has been operated Check if sufficient fuel is in the tank If this is not the case, refill the tank if sufficient fuel is in the tank, proceed as described in the Troubleshooting section or contact a KTM dealer. NOTE: THIS MOTORCYCLE IS EQUIPPED WITH A SAFETY STARTER SYSTEM. THE ENGINE CAN ONLY
BE STARTED WHEN THE TRANSMISSION IS SWITCHED TO IDLE OR THE CLUTCH LEVER IS PULLED, RESPECTIVELY.
THE ELECTRIC STARTER DOESNT CRANK THE ENGINE WHEN THE STARTER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELECTRIC CURRENT IS AVAILABLE: Pull the hand decompression lever 5, start and release the lever.
Starting when the engine is warm or hot
7 Open the fuel tap. Turn on the ignition (ignition key position: ). Switch the gear to neutral (green lamp 1 lights). Switch on the emergency off switch 2. Operate the starter switch 4 without accelerating. Swing up the centerstand Switch on the light before setting off.

Refueling

The LC4 engine needs premium gasoline with an octane number of 95 or higher. CAUTION ! USE UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. BE CAREFUL NOT TO LET FUEL DRIP ON THE PAINTED PARTS, WIPE UP ANY SPILLS IMMEDIATELY. THE FUEL WILL DISCOLOR THE CLEAR COAT AND MAKE IT TURN YELLOW. ! Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE
CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTORS ADVICE IMMEDIATELY.
PERIODIC MAINTENANCE SCHEDULE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Make sure all screws and nuts are tight. Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check screws of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear, force fit and tension. Check screws on pinion and chain sprocket for locking devices and a tight fit. Lubricate chain Check wheel bearings and jerk damper for play

WARNING

MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.
CAUTION ! ! WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC. WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IF THE MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK DO NOT USE TOOTHED WASHERS OR SPRING WASHERS 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. PROPERLY DISPOSE OF OIL, GREASE, FILTERS, FUEL, CLEANSERS, BRAKE FLUID, COOLING LIQUID, ETC. OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY. ALSO OBSERVE THE SAFETY REGULATIONS WHEN HANDLING THESE SUBSTANCES. UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER USED OIL CONTAMINATES 1,000.000 LITERS WATER. IF YOU UNFASTEN SELF-LOCKING NUTS, YOU HAVE TO REPLACE THEM BY NEW ONES. IF YOU UNFASTEN SCREWS AND NUTS SECURED BY LOCTITE, YOU HAVE TO REATTACH AND SECURE THEM IN THE SAME WAY. SEE TECHNICAL SPECIFICATIONS - FASTENING TORQUES ON PAGE 48.

Tool set

The tool kit 1 is locted in the tool box under the right side cover.

Removing the seat

Remove the collar screws 2 from the underside of the fender. Lift the rear of the seat, pull backwards, and unhook it from the oval-head screw 3.
To install the seat, hook the seat into the oval-head screw, set the rear portion down on the frame, and slide it forward. If necessary, press down on the front area of the seat so that the seat catches on the retaining bracket 4. Insert and tighten the collar screw.
Checking and adjusting steering head bearing *
Check steering head bearing for play periodicaly. To check this put motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. To adjust, loosen the five clamp screws 1 of the top triple clamp and turn steering stem bolt clockwise 2 until there is no more play. Dont tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly rap on the triple clamp to avoid tension. Re-tighten the five clamp screws with 15 Nm (11 ft.lb). IF WARNING

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.
At least once a year, the steering head bearings should be greased (Motorex Long Therm 2000).

Bleeder screw front fork

The bleeder screws 3 should now and then be released a few turns to let overpressure, if any, escape from the interior of the fork. To do this, 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 job performed in the course of the periodical maintenance service.

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 BLEEDER SCREWS BEFORE HAVING THE SEALS REPLACED.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 4 are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward.
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with silicone spray or engine oil. Then, push dust-protection bellows into the outer tubes by hand.
YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
Changing the spring preload of the shock absorber
KTM 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 considerably more or less than 75 kg (165 lb), you should change the spring preload A accordingly. 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 1 changes the spring preload by approximately 1,75 mm (0,07 in). Loosen the locking ring 2 with the hook wrench from the tool set. Change the spring preload with the adjusting ring 1 and re-tighten the locking ring.
BASIC SETTING SPRING PRELOAD WP 0118X726.. A = 27 mm (0,9 in)
Checking rubber ring on the WP rear shock absorber
A 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 circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. CAUTION ! ! NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER. THE WARNING

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.

min. 2,5 mm

Lubricating the shock absorber linkage
The bearings in the rocker arm must be greased in regular intervals. For this purpose, a grease nipple 3 is mounted on the rocker arm. ! AFTER CAUTION !
EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALLY IMPORTANT TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.

Checking chain tension

Support the motorcycle on the center stand or side stand, respectively. Switch transmission to neutral. 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. The upper part of the chain B must be tight (see illustr.). Correct chain tension, if necessary! IF WARNING
CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER TRANSMISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE. TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS. 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.
15:45 16:42 A = 0 mm 17:42

Correct chain tension

Loosen collar nut 1, loosen counter nuts 2, and turn right and left adjusting screws 3 equally far. Tighten counter nuts 2. Before tightening the wheel spindle, verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. Tighten collar nut 1 with 80 Nm (59 ft.lb). IF WARNING
YOU DONT HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
NOTE: The large adjusting range of the chain adjusters (32mm) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters 4 can be rotated by 180. CAUTION ! ! ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws 1 on the left fork leg. Then loosen the collar nuts 2 before loosening the clamp screws 3 on the right fork leg. Hold the front wheel and withdraw the wheel spindle 4. Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm ALLAN/IMBUS key while pulling. CAUTION ! ! DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED. ALWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT DAMAGING OF THE BRAKE DISC.
Before mounting, check if the left and the right 5 distance bushing are correctly positioned in the shaft seal rings. Extremely soiled distance bushings should be removed, cleaned and regreased. To mount the front wheel lift it into the fork and insert the brake disk into the brake caliper. Position the front wheel and mount the wheel spindle. Mount the collar nut 2, tighten the clamping sceews on the right side 3 to prevent the wheel spindle from turning and tighten the collar nut to 40 Nm (30 ft.lb). Loosen the clamping screews on the right side, Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs. Then tighten clamping screws 1 and 3 to a max. torque of 10 Nm (7 ft.lb). IF WARNING
YOU DONT HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE 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 by frame so that the rear wheel no longer touches the ground. Loosen the collar nut 6, hold the rear wheel and pull out the wheel spindle 7 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 rear sprocket 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 (MOTOREX LONG THERM 2000) TO PREVENT THE THREAD FROM JAMMING. ALWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT DAMAGING OF THE BRAKE DISC. NOTE: When removing the rear wheel always check the damping rubbers. The rear wheel is remounted in reverse order. Before tightening the collar nut to 80 Nm (59 ft.lbs), push the rear wheel forwards so that the chain tensioners lie on the tension screws. IF WARNING

NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES. THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE. 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 NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PURPOSE, RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST 200 KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN. FOR REASONS OF SAFETY, IT IS RECOMMENDED TO EXCHANGE THE VALVE INSERT WHENEVER A NEW TIRE IS MOUNTED.

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. For checking, tap on each spoke with the blade of a screw driver (see illustration). A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE. EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING.THE SPOKES MUST BE TENSIONED TO 4 NM.
Socket for electric accessories
A socket is provided in the cockpit for electric accessories, e.g. GPS, roadbook, cell phone, etc. The socket has a 12V voltage and is protected by a 5 A fuse. Do not plug power consumers with a higher requirement into this socket. You can also use this socket to charge the battery with a maximum of 14.4 volts and 4 amperes. CAUTION ! ! REMEMBER THAT ELECTRIC ACCESSORIES WILL RUN DOWN THE BATTERY. THE DIGITAL SPEEDOMETER CAN BE DESTROYED IF THE ABOVE CHARGING EXCEEDED.

LIMITS ARE

Battery
The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: Remove screws 1 and swing retaining bracket and voltage regulator out of the way. First disconnect the negative and then the positive pole of the battery. Remove battery. When replacing, connect first the positive and then the negative pole. IF WARNING
ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS. IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER. IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR. THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY. DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN. ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES.

POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT, USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE.
A mixture of 60% antifreezer and 40% water is used as cooling liquid. How-ever, the anti-freeze protection must be at least -25 C (-13 F). Aside from antifreezing protection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water. ! FOR THE COOLING ANTI-FREEZE). USING COOLANT FOAMING. CAUTION !
SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND
Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap 3; a water temperature rising up to 120 C (248 F) is admissible, without fear of problems.
Checking the cooling liquid level
The cooling liquid should be 10 mm (0,4 in) above the cooling elements when the engine is cold (cf. diagram). In the event of the cooling liquid being drained, always fill the system before hand, then top off while the engine is running. IF WARNING

when engine is cold

Cleaning the air filter *
It is very important for the engine's life expectancy to clean the air filter regularly. To clean the air filter, remove screws 1 and the filter box cover. Detach retaining clip 2 and remove the air filter 3 including the filter holder 4 from the filter box. Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid. Products required for a professional maintenance of the air filter are available from TWIN AIR. Press out the water from the air filter but do not wring and allow the filter to dry. Lubricate the dry air filter thoroughly with high-grade filter oil, rubbing to coat the entire filter surface. Clean the filter box and cover and check the carburetor connection boot for damage. Mount the air filter on the filter holder, position in the filter box (make sure to center) and fix with the retaining clip. Check whether the air filter is positioned correctly and mount the filter box cover.

THE FOAM.

RECOMMENDS THE PRODUCTS MADE BY

! TWIN AIR

FOR AIR FILTER
NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE
MAINTENANCE. FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER.
AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS

NOT MOUNTED CORRECTLY.

Adjusting the throttle cable *

3-5 mm

When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm (0.11-0.19 in).
If a correction is necessary, start by removing the tank. Slide back the protection cover 1. To set the backlash, loosen the counter nut 2 and turn the adjusting screw 3 accordingly. Then, fasten the counter nut and slide the protection cover back on. Make sure that the throttle grip will return to the idle position automatically once you let go of it. To check the correctness of this setting, start the engine, turn the handlebar left and right, in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise, you have to increase the backlash of the throttle cable.
Checking the oil level of the hydraulic clutch
To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws 4 and cover 5 together with the rubber boot 6. The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell Naturelle HF-E15).Biodegradable hydraulic oil is available from your KTM dealer (50ml). CAUTION ! ! KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
Changing the original position of the clutch lever
The adjusting screw 7 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar.

Oil and screen filter change, bleeding of the oil system *
Note: The frame breast pipe is integrated into the oil circuit for the sake of more effectively cooling the motor oil. It is thus important when changing the oil to also remove the fine screen filter, to drain the motor oil from the breast pipe and to de-aerate the oil system. If the oil system is not bled at all or bled insufficiently, the bearings of the engine will not get enough lubrication, which in turn may result in engine failure. Therefore, we recommend that you have the engine oil changed by your authorized KTM mechanic. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void. 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 IS VERY HOT - DO NOT BURN YOURSELF. Place the motorcycle on a horizontal surface. Remove 5 screws to remove the engine guard bn. Remove the two screw plugs bo and bp and drain oil into a vessel. Loosen the fine filter 6 with an oil-filter wrench and unscrew by hand. Remove the two plugs bn and bo, and drain oil into a container.
CAUTION ! ! PLUG A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. The screw bq must be removed to allow the motor oil to flow out of the frame breast pipe. Clean the plugs thoroughly with petroleum and compressed air in order to remove any metal filings. After the oil has drained completely, clean the sealing areas and remount the plugs together with their gaskets. Tighten plug bo with 30 Nm and plug bp with 20 Nm. Tighten the screw bq with 10 Nm. Clean sealing surfaces on the frame breast pipe br, fill new fine screen filter with engine oil, and oil rubber gasket bs. Replace fine screen filter and screw it back in place, your bare hand will do. Remove screw connection on the clutch cover, fill with 1,3 litre engine oil and attach plug again. 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 FRONT PIPE OF THE FRAME, YOU MUST BLEED THE OIL SYSTEM !
To facilitate bleeding of the oil system, we have added a hose connection piece and a plastic hose to the set of tools. Take an empty oil can (1 liter) and drill a 7 mm-diameter hole into the lid. Screw the hose connection piece into the lid from the outside, and secure it from the inside with the M8 hexagon nut. Slip the plastic hose onto the hose connection piece, and you will have your filling tool.

No values are visible in the Tripmaster display. No speed display.
Main fuse melted through Defective sensor cable or oxidized socket connector.

CLEANING

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 trade washing detergent and a sponge. The hard dirt can be removed before 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 DISTURBINGS OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS. You should use normal trade-mark detergents to clean the engine. Strongly dirted parts should be cleaned additionally with the help of a paint brush. Befor cleaning with water, plug the exhaust pipe to prevent water ingress 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. Due to the heat, the water also evaporates at the unapproachable 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 motorcycle is allowed to evaporate. After the motorcycle has cooled down, oil and grease all sliding and pivot points. 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, light switch and the socket connectors with contact spray.
CONSERVATION FOR WINTER OPERATION
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 precautions against the aggressive road salt. Thoroughly clean and let the motorcycle dry after every ride. 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! !

STANDARD ADJUSTMENT - FORK
WP 4860 MXMA 1418X14 4,4 N/mm 4 mm 120 mm ca 420 ccm SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
WP BAVP3612 0118X7 70/mm (0,9 in)
Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil
Compression adjuster Rebound adjuster Spring Spring preload
TIGHTENING TORQUES - CHASSIS 640 LC4 ADVENTURE
Collar nut front axle Collar nut rear axle Shock absorber top/bottom Collar screws brake disk front/rear Screw brake caliper front Bearing bolt linkage arm/frame Collar nuts rocker arm bolts Engine mounting screw Sprocket screws on nuts Collar nut swingarm bolt Clamping screws top triple clamp (MXMA 4860) Clamping screws bottom triple clamp (MXMA 4860) Clamping screws fork stubs Spoke nipple Other screws on chassis M16x1,5 M20x1,5 M10 M6 (10,9) M8 M12 M14x1,5 M10 M8 M14x1,5 M8 M8 M8 M4 M6 M8 M10 M6 M8 MNm 80 Nm 45 Nm Loctite 243 + 10 Nm Loctite 243 + 25 Nm 60 Nm 100 Nm 45 Nm Loctite 243 + 35 Nm 100 Nm 20 Nm 15 Nm 10 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm (30ft.lb) (59ft.lb) (33ft.lb) (7ft.lb) (19ft.lb) (44ft.lb) (74ft.lb) (33ft.lb) (25ft.lb) (74ft.lb) (15ft.lb) (11ft.lb) (7ft.lb) (3ft.lb) (7ft.lb) (19ft.lb) (33ft.lb) (11ft.lb) (22ft.lb) (37ft.lb)
Other colllar nuts an chassis

HEAD WORD INDEX

Page Serial number locations..5 Chassis number...5 Engine number, engine type..5 Operation instruments..5 Clutch lever...5 Hand decompression lever..5 Hand brake lever..6 Choke lever...6 Ignition lock with 3 switch positions..6 Multi-functional digital speedometer.7 Setting options in the display..8 Indicator lamps...9 Tachometer...9 Combination switch..10 Starter tip switch, emergency OFF switch, light switch.10 Filler cap....10 Fuel taps....10 Shift lever...11 Kickstarter...11 Foot brake pedal...11 Compression damping of fork..12 Rebound damping of fork...12 Compression damping of shock absorber..12 Rebound damping of shock absorber..12 Baggage carrier..12 General tips and warnings for starting the motorcycle.14 Instructions for initial operation..14 Running in...14 Driving instructions...15 Check the following before each start..15 Starting when the engine is cold...16 Starting when the engine is waorm or hot..16 What to do when the engine is flooded..16 Kickstart instructions...17 Starting off...17 Shifting, Riding..17 Braking...17 Stopping and parking...18 Refueling...18 Periodic maintenance-schedule..20 Maintenance work on chassis and engine..22 Tool set...22 Removing the seat..22 Checking and adjusting steering head bearing..23 Bleeder screws front fork...23 Cleaning the dust sleeves of the telescopic fork.23 Changing the spring preload of the shock absorber.24 Checking rubber ring on the WP rear shock ansorber..24 Lubricate shock absorber linkage...24 Checking chain tension..25 Page Correct chain tension...25 Chain maintenance...26 Chain wear...26 General information about KTM disc brakes.27 Adjusting of free travel at the hand brake lever.28 Checking of brake fluid level - front brake.28 Refilling the front brake fluid reservoir..28 Checking the front brake pads..28 Changing the basic position of the foot brake pedal.29 Check the rear brake fluid level..29 Refilling the rear brake fluid reservoir..29 Checking the rear brake pads...29 Dismounting and mounting the front wheel.30 Dismounting and mounting the rear wheel..30 Checking the shock absorbtion rubbers in the rear hub.31 Tires, air pressure...31 Checking spoke tension..32 Socket for electric accessories...32 Battery...33 Charging the battery...33 Fuses...34 Removing and mounting the headlight mask..34 Replacing the headlight bulb..34 Exchanging the brake light and tail light blub..35 Removing the tank..35 Cooling system..36 Checking the cooling liquid level...36 Cleaning the air filter...37 Adjusting the throttle cable..38 Checking the oil level of the hydraulic clutch..38 Changing the orginal position of the clutch lever.38 Adjusting the choke cable play..39 Checking the adjustment of the hand decompression cable 39 Adjusting idling speed..39 Draining of float chamber of the carburetor.40 Engine oil...40 Checking the engine oil level..40 Oil circuit...41 Oil and fine screen filter change, bleeding of the oil system 41 Changing oil filter..42 Trouble shooting...43 Cleaning....46 Conservation for winter operation..46 Storage...46 Re-initation after time of storage..46 Technical specifications - engine..48 Technical specifications - chassis..50 Head word index...52 Wiring diagram..appendix

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. 1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases. 2) Removal or puncturing of any part of the intake system. 3) Lack of proper maintenance. 4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

WARNING STATEMENT:

This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

640 LC4 ADVENTURE

IMPORTANT Before you go for the first ride on your motorbike read the entire Users Guide carefully!
IMPORTANT To avoid oil spill through crankcase breather, never exceed top mark at operating temperature!
WARNING THIS SHOCK ABSORBER CONTAINS NITROGEN GAS UNDER HIGH PRESSURE. DO NOT ATTEMPT REFILLING OR REBUILDING THE SHOCK, SINCE THE SHOCK MAY BE DAMAGED. REFER TO THE OWNERS MANUAL

KTM SPORTMOTORCYCLE AG

5230 Mattighofen Austria Internet: www.ktm.at

321057

FUELRECOMMENDATIONSKTM4STRMODELS
From model year 2000 Status January 2011
250 SX-F 250 SXS-F 250 SX-F 250 EXC RACING 250 EXC-G RACING 250 EXC RACING SIX DAYS 250 EXC-F (SIX DAYS) 250 EXC-F Champions Edition 250 XCF-W 250 XC-F 250 XCF-W Champions Edition 350 EXC FACTORY RACING 350 SX-F 350 XC-F 400 EXC RACING 400 EXC 400 EXC-G RACING 400 EXC RACING SIX DAYS 400 EXC FACTORY RACING 400 MXC RACING 400 LC4-E 400 LC4-E Mil Bronze 400 LS-E/Mil 400 SC 400 SXC 400 SX RACING 400 XC-W 450 XC-G RACING 450 XC CROSS COUNTRY 450 MXC-G RACING 450 EXC RACING 450 EXC RACING SIX DAYS 450 EXC FACTORY RACING 450 EXC-G RACING 450 EXC-R (SIX DAYS) 450 EXC (SIX DAYS) 450 EXC Champions Edition 450 Rally Factory 450 SX-(F) 450 SXS-(F) 450 XC + XC-W 450 XC-F 450 XC-W Champions Edition 450 XC-W (SIX DAYS) 450 SMR 450 SMS

model year

2006-2011 2006-2002-2006 2004-2005 2002-2003 2007-2007-2011 2007-2011 2000-2007 2009-2011 2002/04-06 2001-2001-2000-2003-2005 2003-2007 2003-2003-2009-2003-2011 2003-2008-2008-2011 2004-2010 2004
RON 80-90 RON 91 PON 77-86.6 PON 87.6

RON 95 PON 91

RON 98 PON 94

Comment: after setting the ignition curve for low-octane fuel Notes on fuel quality (for all models) Page 6
505 SX(S)-F 505 XC-F 520 MXC RACING 520 EXC RACING 520 EXC RACING SIX-DAYS 520 EXC-G RACING 520 SX RACING 525 XC-G RACING 525 XC DESERT RACING 525 XC + XC-W 525 MXC DESERT RACING 525 MXC-G RACING 525 EXC RACING 525 EXC FACTORY RACING 525 EXC RACING SIX-DAYS 525 EXC-G RACING 525 SX RACING 525 SX SUPERMOTO 525 SMR 530 EXC-R (SIX-DAYS) 530 EXC (SIX DAYS) 530 EXC Champions Edition 530 XCR-W 530 XC-W (SIX DAYS) 540 SXS RACING 560 SMR
2007-2008 2008-2009 2001-2002 2000-2002 2001-2000-2002 2005-2006 2005-2003-2005 2003-2005 2003-2003-2007 2003-2006 2003-2006 2004-2005 2004-2009-2008 2009-2011 2000-2006 2006-2007

RON 95 PON 91

450 XC ATV 525 XC ATV 450 SX ATV 525 SX ATV
2008-2009 2008-2011 2009-2010 2009-2010

RON 95 PON 91

model 125 DUKE 620 LC4 SUPERCOMPETITION 620 SC SUPERMOTO 625 SXC 625 SMC 625 SUPERCOMPETITION 625 SC SUPERMOTO 640 LC4 ENDURO 640 LC4 ENDURO 640 LC4 SUPERMOTO 640 LC4 SUPERMOTO 640 LC4 ADVENTURE 640 LC4 ADVENTURE 640 DUKE II 640 DUKE II 650 RALLY 660 RALLY 660 SMC 660 SMS 660 SUPERMOTO FACTORY 690 SUPERMOTO (Limited Edition) 690 SUPERMOTO PRESTIGE 690 SUPERMOTO R 690 RALLY 690 ENDURO / R 690 SMC 690 DUKE / R 950 ADVENTURE 950 ADVENTURE S 950 SUPER ENDURO ( R ) 950 SUPERMOTO 950 SUPERMOTO R 990 SUPERMOTO 990 SUPERMOTO R 990 SUPERMOTO T 990 SUPER DUKE ( R ) 990 ADVENTURE R 990 ADVENTURE ABS 990 ADVENTURE S 990 AVENTURE DAKAR 1190 RCRC8 TRACK 1190 RC8 R 1190 RC8 R Model year 2011 2000-2001 2000-2001 2003-2007 2004-2002 2000-2003 2004-2006 2000-2003 2004-2006 2000-2003 2004-2007 2000-2003 2004-2000-2006 2003-2002-2003 2007-2008-2009 2007-2010 2008-2011 2008-2011 2008-2011 2003-2005 2003-2005 2006-2009 2005-2007 2006-2008 2008-2009 2009-2011 2009-2011 2005-2011 2009-2011 2006-2010 2006-2008-2009-RON 80-90 PON 77-86.6 RON 91 PON 87.6 RON 95 PON 91 RON 98 PON 94 RON 100 PON 95.8
FUELRECOMMENDATIONSKTM2STRMODELS
50 SENIOR ADVENTURE 50 SENIOR ADVENTURE 50 JUNIOR ADVENTURE 50 MINI ADVENTURE 50 SX PRO SENIOR LC 50 SX PRO JUNIOR LC 50 SX SENIOR 50 SX JUNIOR 50 SX JUNIOR 50 SX 50 SUPERMOTO 60 SX 65 SX 65 SX 65 XC 85 SX 85 SX 85 XC 105 SX 105 SX 105 XC 125 EXC 125 EXC 125 EXC Champions Edition 125 EXC SIX DAYS 125 EXC SIX DAYS 125 SX 125 SX 125 SXS 125 SXS 144 SX 150 SX / XC 200 MXC 200 EXC 200 EXC / XC-W 200 EXC-GS 200 EXC SGP GS
2000-2005 2006-2007 2000-2003 2000-2002 2002-2005 2002-2005 2000-2001 2000-2001 2006-2009 2006-2000 2000-2005 2006-2011 2008-2009 2003-2008-2009 2004-2009 2000-2007 2008-2001-2007 2008-2011 2000-2007 2008-2011 2000-2002 2003-2009 2007-2008 2009-2011 2000-2003 2000-2007 2008-2011 2000-2002 2000-2002

RON 95 PON 91 1:40-1:60

RON 95 PON 91 1:40

RON 95 PON 91 1:60

RON 98 PON 94 1:40

RON 98 PON 94 1:60

Anmerkung: unleaded fuel with at least RON xx or PON yy, mixed with high grade two stroke oil (Motorex Cross Power 2str.) at the assigned mixture ratio (e.g.: 1:40). Notes on fuel quality (for all models) Page 6
200 XC 200 XC 200 XC-W 200 XC-W 200 SX 250 EXC 250 EXC 250 EXC SIX DAYS 250 EXC SIX DAYS 250 EXC FACTORY 250 MXC 250 XC 250 XC 250 XC-W 250 XC-W 250 SX 250 SX 250 SXS 250 SXS 250 SXS 300 EXC 300 EXC (E) 300 EXC SIX DAYS 300 EXC (E) SIX DAYS 300 XC 300 XC 300 XC-W 300 XC-W 300 MXC 380 EXC 380 MXC 380 SX
2006-2007 2008-2009 2006-2007 2008-2011 2003-2004 2000-2007 2008-2011 2001-2007 2008-2000-2005 2006-2007 2008-2011 2006-2007 2008-2011 2000-2007 2008-2011 2000-2001 2003-2004 2005-2008 2000-2007 2008-2011 2001-2007 2008-2011 2006-2006-2007 2008-2011 2000-2005 2000-2002 2000-2002 2000-2002

MODELS WITH SEPARATE LUBRICATION
50 MINI ADVENTURE 50 SX MINI 125 EXE EXE SUPERMOTO SUPERMOTO 80
2003-2008 2009-2011 2000-2001 2000-2001 2000-2001 2000-2001

RON 91 PON 87.6

RON 95 PON 91
NOTES ON FUEL QUALITY (for all models)
Only use lead-free fuel that is in compliance with the EN 228 standard with the corresponding octane
number (RON.) or is equivalent to these specifications.
It is safe to use fuel with up to 10 % ethanol (E10 fuel). Do not use fuel made from methanol (e. g. M15, M85, M100) or fuel with more than 10 % ethanol (e. g.

E15, E25, E85, E100).