KTM 625 LC4 SUPERCOMPETITION Owner'S Handbook Manual Download

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OWNERS HANDBOOK

MANUALE D’USO

MANUEL D’UTILISA

TION

MANUAL DE INSTRUCCIONES

2002

BEDIENUNGSANLEITUNG

Art.Nr

. 3.210.20 10/2001

625

LC4 SUPERCOMPETITION

625

LC4 SC SUPERMOTO

Summary of Contents for 625 LC4 SUPERCOMPETITION

Page 1: ...OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art Nr 3 210 20 10 2001 625 LC4 SUPERCOMPETITION 625 LC4 SC SUPERMOTO...

Page 2: ...by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or d...

Page 3: ...ue in your case you will be able to use this Owner s Handbook to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to...

Page 4: ...about KTM disc brakes 19 Adjusting of free travel at the hand brake lever 20 Checking brake fluid level front brake 20 Refilling the front brake fluid reservoir 21 Check the front brake pads 21 Replac...

Page 5: ...ured at outer edge Hand decompression lever The 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...

Page 6: ...e The display will change and briefly show the diameter of the front wheel in millimeters Then it automatically switches to the ODO mode ODO The ODO mode shows the speed and the total kilometers trave...

Page 7: ...he reserve tank approximately 1 5 liters cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the...

Page 8: ...Remove closing cap A By using the knob 1 COM the degree of damping of the compression can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during comp...

Page 9: ...bounding STANDARD ADJUSTMENT WP 0118W714 position 3 625 SC WP 0118W721 position 5 625 SC SUPERMOTO Rebound damping of shock absorber With the setting wheel 2 the degree of damping of the rebound can b...

Page 10: ...ters 620 miles During this break in time you should ride your motorcycle in different conditions roads easy off road terrain The following table shows you the maximum velocity values in the different...

Page 11: ...ssure deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way tha...

Page 12: ...le closed and push the kickstarter hard ALL THE WAY What to do when the engine is flooded Pull in the hand decompression lever open the throttle fully kick the kick starter through the stroke 5 to 10...

Page 13: ...AVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVER REV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL LONG WH...

Page 14: ...s horn 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 fo...

Page 15: ...ar intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber...

Page 16: ...F 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 CIRC...

Page 17: ...s and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray Then push dust protection bellows into the outer tubes by hand...

Page 18: ...and in the rear Check set distance of the magnetic sensor The distance between magnet and sensor 5 must be 2 4 mm otherwise malfunctions on the speedometer might occur This distance can be corrected b...

Page 19: ...ds appr 30 mm 1 2 in from the end of the chain sli ding component until the upper part of the chain is tensioned see illustration Now the distance A between chain and swingarm should be 0 mm respec ti...

Page 20: ...ssary Chain wear In 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 kilogram 33 lb upwards see figure Now on...

Page 21: ...hould replace it as soon as possible by DOT 5 1 Never use DOT 5 braking fluid It is based on silicone oil and has a purple color Gaskets and brake hoses are not compatible with it BRAKE DISCS Wear red...

Page 22: ...OULD 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 COMP...

Page 23: ...and plug Overflown or spilled brake liquid must be rinsed off with water Mount the screw and fix the brake fluid reservoir to the frame always making sure to prevent kinks in the connecting hose WARNI...

Page 24: ...ight fork leg Hold the front wheel and withdraw the wheel spindle 6 Note The wheel spindle can be withdrawn more easily by turning it mode rately with a 6 mm ALLAN IMBUS key while pulling Carefully re...

Page 25: ...rear wheel is remounted in reverse order Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws Dismounting and mounting...

Page 26: ...fic regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm Tire pressure should be checked regularly on a cold...

Page 27: ...OF CHILDREN IN CASE COOLANT IS INGESTED GO SEE A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR A mixture of 40 anti freeze liquid and 60 w...

Page 28: ...ront glass fiber pack 3 must be replaced more often than the rear pack 4 To replace the front glass fiber yarn pack remove the silencer Remove the front cap 5 pull the front glass fiber yarn pack out...

Page 29: ...screwed in up to the stop without causing 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 a larger id...

Page 30: ...en 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 4 accordingly Checking the adjustment of...

Page 31: ...e oil onto the piston pin bearing and piston head The second oil lead takes the main flow of oil to the microfilter 5 which filters out even the finest impurities The cleaned engine oil is pumped thro...

Page 32: ...r with a rag Allow the engine to run at idle until oil runs out of the oil line 3 Turn the engine off Install seal rings and the jet screw Torque the jet screw to 10 Nm 7 ft lb and check for leaks Cha...

Page 33: ...riods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off wh...

Page 34: ...l too thin viscosity Capacitor or voltage regulator faulty REMEDY Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor replace the float Clean or replace air fil...

Page 35: ...oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves wi...

Page 36: ...traight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless D...

Page 37: ...M22x1 5 30 Nm 22ft lb Magnetic plug M12x1 5 20 Nm 15ft lb Plug bypass valve M12x1 5 20 Nm 15ft lb Hollow screws oil lines M8x1 10 Nm 7ft lb Hollow screws oil lines M10x1 15 Nm 11ft lb Jet screw clutc...

Page 38: ...2002 625 SC 625 SC SUPERMOTO Frame Central chrome moly steel frame Fork White Power 4357 MXMA Wheel travel front rear 295 320 mm 11 8 12 8 in 270 320 10 8 12 8 in Rear suspension Central shock absorbe...

Page 39: ...4 Spring 4 2 N mm 5 0 N mm Spring preload 5 mm 9 mm Air chamber length 140 mm 130 mm Fork oil SAE 5 SAE 5 STANDARD ADJUSTMENT FORK 625 SC 625 SC SUPERMOTO WP 0118W714 WP 0118W721 Compression adjuster...

Page 40: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321020...

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