background image

ENGLISH

30

                   

+

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API:  SG, SH

TEMPERATUR

8

7

1

2

3

4

5

6

9

10

11

Engine oil

Only use synthetic high-quality oils (Shell Advance Ultra 4) meeting or sur-
passing the quality requirements of API classes SG, or SH (for specifications
see containers). 

!

CAUTION

!

I

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE

.

Checking engine oil level

Allow the engine to run at idle speed for about 4 minutes. Turn off the
engine and place the motorcycle on a flat, level surface (center stand). Wait
5 minutes, unscrew and remove the oil dipstick, and wipe it clean with a
cloth.

SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN.

The oil level should be between the two marks on the dipstick, however, it
must never rise above the MAX mark. Otherwise, engine oil would get into
the air filter box by way of the engine venting system.
Add engine oil if necessary.

!

CAUTION

!

– I

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE

ENGINE

.

– C

HECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE

READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL

.

– D

O NOT OVERFILL THE ENGINE CASE

.

– D

O NOT UNDERFILL THE ENGINE CASE

.

Check the engine for leaks.

Oil circuit

The oil pump 

1

pumps the engine oil past the by-pass valve 

2

through the

oil filter 

3

. After the oil filter, an oil lead branches off to a jet 

4

which

sprays engine 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 through the oil lead
and the clutch cover into the crankshaft to the connecting rod bearing 

6

and drips into the crankcase. An additional oil pump 

7

sucks the engine oil

out of the crankcase and pumps it through the oil line 

8

to the gear wheels

of the 4th and 5th gear. Via the gear wheels, the engine oil reaches the oil
sump. The timing chain 

9

runs through the oil sump and transports the

engine oil upwards to the cylinder head. Through the bore 

bk

the oil 

reaches the camshaft 

bl

and the valves.

Changing the engine oil *

The engine oil change is to be carried out when the engine is still warm.

WARNING

A

N 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 (

bm

and

bn

), and drain oil into a container.

!

CAUTION

!

T

HE 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
order to remove the metal abrasion. After all the oil has drained through,
clean raised and flat faces and install plugs with seals. Tighten plug 

bm

with

30 Nm (22 ft.lb)and plug 

bn

with 20 Nm (15ft.lb).

Remove oil dipstick on the clutch cover and fill with 1.45 litre engine oil (i.e.
Shell Advance Ultra 4).
Warm up engine, check engine oil level and refill up to the marking MAX.
Finally check the oil system for leaks.

MAX

MIN

A

13

12

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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