KTM 400LC4 User guide

BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
OWNER’S HANDBOOK
OWNER’S HANDBOOK
MANUALE D’USO
MANUALE D’USO
MANUEL D’UTILISA
MANUEL D’UTILISATION TION
MANUAL DE INSTRUCCIONES
MANUAL DE INSTRUCCIONES
400/640 LC4
400/640 LC4R
SUPERMOTO
‘99
‘99
AR
ART T. NR. 3.205.60 . NR. 3.205.60
10.98
10.98

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1
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 YOUR
BODY AND YOUR LIFE.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE
IS NOT ROAD-SAFE ANYMORE.
Please insert the series numbers of your motorcycle in the boxes below
Frame number
Engine number
Stamp of dealer
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes of mainten-
ance, repair or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser
or while it is in use; and
(b) the use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
COMSUMER INFORMATION FOR AUSTRALIA ONLY

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2
Introduction
We would like to congratulate you on your purchase of a KTM motorcycle.
You are now owner of a sporty and modern motorcycle which you are bound to
have a great time with, provided you care for it properly. This manual will furnish
you with 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 modi-
fications in the meantime due to development in our motorcycle design.
Many motorcyclists have a good working knowledge of motorcycle mechanics; if
this is true in your case, you will be able to use this manual 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 have a professional KTM dealer perform
those steps marked *described 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
intervals. Heeding these guidelines will significantly increase the life of your
motorcycle. Have services carried out by a KTM dealer so that your warranty
claim remains intact.
We wish you a lot of fun when driving !
KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the
beginning of an on-going total re-engineering quality plan for a brighter tomorrow.
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3
Page
SERIAL NUMBER LOCATIONS .............................................4
Chassis number ................................................................4
Engine number, engine type.............................................4
OPERATION INSTRUMENTS ...............................................4
Clutch lever ......................................................................4
Hand decompression lever................................................4
Choke lever......................................................................5
Hand brake lever..............................................................5
Speedometer, indicator lamps...........................................5
Ignition lock .....................................................................5
Combination switch..........................................................6
Starter tip switch, emergency OFF switch .........................6
Filler cap...........................................................................6
Fuel..................................................................................6
Fuel tap............................................................................7
Shift lever .........................................................................7
Kickstarter ........................................................................7
Foot brake pedal ..............................................................7
Compression damping of fork ..........................................8
Rebound damping of fork ................................................8
Compression damping of shock absorber .........................8
Rebound damping of shock absorber ...............................8
Baggage carrier ................................................................8
DRIVING INSTRUCTIONS ....................................................9
PERIODIC MAINTENANCE-SCHEDULE ..............................13
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........14
Tool set ..........................................................................14
Removing the seat..........................................................14
Checking and adjusting steering head bearing................15
Changing the spring preload of the shock absorber........15
Lubricate shock absorber linkage ....................................15
Checking rubber ring on the rear shock absorber............16
Checking chain tension...................................................16
Correct chain tension......................................................16
Chain maintenance.........................................................16
Chain wear.....................................................................17
General information on KTM disc brakes ........................17
Adjisting of free travel at the hand brake lever ...............17
Checking of brake fluid level - front brake......................18
Refilling the front brake fluid reservoir............................18
Checking the front brake pads........................................18
Changing the basic position of the foot brake pedal .......18
Check the rear brake fluid level ......................................19
Refilling the rear brake fluid reservoir .............................19
Checking the rear brake pads .........................................19
Dismounting and mounting the front wheel...................20
Dismounting and mounting the rear wheel.....................20
Checking the shock absorbtion rubbers in the rear hub .......21
Tires, air pressure............................................................21
Checking spoke tension..................................................21
Battery ...........................................................................22
Charging the battery ......................................................22
Main fuse.......................................................................23
Fuses for individual power-consuming units ...................23
Replacing the headlight bulb ..........................................23
Replacing the parking light bulb .....................................23
Replacing the brake light and tail light bulb ....................24
Cooling system...............................................................24
Checking the cooling liquid level ....................................25
Adjusting idling speed ....................................................25
Adjusting the throttle cable ............................................25
Adjusting the choke cable...............................................26
Adjusting the clutch cable...............................................26
Checking the adjustment of the hand decompression cable ..... 26
Engine oil .......................................................................26
Checking the engine oil level..........................................26
Oil circuit........................................................................27
Oil change and bleeding of the oil system ......................27
Changing the fine screen filter........................................28
Changing oil filter ..........................................................28
TROUBLE SHOOTING........................................................29
CLEANING..........................................................................32
CONSERVATION FOR WINTER OPERATION ....................32
STORAGE ...........................................................................32
Re-initation after time of storage....................................32
TECHNICAL SPECIFICATIONS - CHASSIS...........................33
TECHNICAL SPECIFICATIONS - ENGINE ..........................34
WIRING DIAGRAM................................................APPENDIX
Index

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4
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Write this number into the relevant area on page 1.
Engine number, engine type
The engine number and engine type are stamped on the right hand side of
the engine below the chain sprocket. Write this number into the relevant
area on page 1.
Clutch lever
The clutch lever 1is fitted on the left hand side of the handle bar. When
engine is cold, there should allways be a play of 1–3 mm (0,04–0,1 in) at
this lever (measured 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 lever
The hand decompression lever 2is only used in two special cases:
a)When the engine stalled.
It is possible that the starter motor is not able to crank the engine on the
next attempt. This is due to the fact that the automatic decompressor
doesn’t work properly. If this happens, pull the manual decompression
lever and start again. Afterwards normal starting will be possible.
b) When you want to push the motorcycle.
While pushing, pull the hand decompression lever to make it easier to get
the engine going.
!
CAUTION
!
THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED
(SEE MAINTENANCE WORK). A LACK OF PLAY IN THE HAND DECOMPRESSION LEVER CAN
RESULT IN ENGINE DAMAGE.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1-3 mm
1
2

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5
Choke lever
If the choke lever 1is pulled backwards, a bore will be opened in the
carburetor through which the engine may draw in additional fuel. This
produces a „rich“ fuel/air mixture necessary for cold start. If the choke lever
is pushed forward up to the stop, the bore will be closed again. In this
position the choke cable must have a play of approx. 2 mm.
!
CAUTION
!
IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER SYSTEM
CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN
UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON AND CYLINDER.
Hand brake lever
The hand brake lever is mounted on the handlebar on the right and
actuates the front 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 LOOKED OVER BY A KTM DEALER.
Speedometer, indicator lamps
The mileage indicator Ain the speedometer 2indicates overall mileage. The
day mileage indicator Bcan be set to 0 by means of the setting wheel C.
Turn the setting wheel forward until only zeros can be seen in the display.
The green indicator lamp flashes when the flasher light is working in
the same rhythm as the flasher light.
The green indicator lamp lights up when the gear is switched to idle.
The blue indicator lamp lights up when the high beam is on.
The red cooling liquid temperature warning lamp lights up at a
cooling liquid temperature of 110°C (230°F).
!
CAUTION
!
IF THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP WHILE YOU ARE
DRIVING, THE COOLING SYSTEM IS PROBABLY DEFECT. IMMEDIATELY STOP THE ENGINE
AND CHECK THE COOLING LIQUID LEVEL (SEE PAGE 25). DRIVING WITH THE WARNING
LAMP ON WILL CAUSE ENGINE DAMAGE.
Ignition lock with 4 switch positions
Switch positions of ignition lock 3:
Ignition off, light off (engine can't be started)
Ignition on, light off (engine can be started)
Ignition on, light on (engine can be started)
Ignition off, light off, handlebar blocked
To switch the ignition to position turn the ignition key to position
and firmly press it into the lock. Turn the handlebar all the way to
the left, then turn the ignition key to the left.
The ignition key can be withdrawn in position and .
Ignition lock with 3 switch positions
Switch positions of ignition lock 4:
Ignition off, light off (engine can't be started)
Ignition on, light on (engine can be started)
Ignition off, light off, handlebar blocked
To switch the ignition to position turn the ignition key to position
and firmly press it into the lock. Turn the handlebar all the way to
the left, then turn the ignition key to the left.
The ignition key can be withdrawn in position and .
1
2
3
4
A
B
C

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6
Combination switch
The rocker switch LIGHTS 1actuates the high beam or low beam.
= High-beam light
= Low-beam light
The indicator switch 2returns to central position after actuation.
Press flasher switch towards switch housing to switch off the flasher.
The horn is sounded with button 3.
The light signal (high beam) is actuated with button 4.
Starter tip switch, emergency OFF switch
Use the starter tip switch 5to operate the electric starter.
!
CAUTION
!
MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST
5 SECONDS BEFORE TRYING AGAIN.
The emergency OFF switch 6is mainly a safety and emergency switch and
should normally be ON.
If this symbol is visible on the switch, the engine can be started
(i.e. the ignition circuit and the starter circuit are switched on).
If this symbol is visible on the switch, the engine can not be started
(i.e. the ignition circuit and the starter circuit are interrupted).
Filler cap
The filler cap 7can be locked and is provided with a fuel evaporation con-
trol system.
To open the cap insert the ignition key, turn it 90° counterclockwise, then
lift off the filler cap.
To close the tank insert the filler cap, turn the ignition key 90° clockwise
and take out the key.
Fuel
The 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.
–I
F YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER, ALWAYS KEEP IN
MIND THAT LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER. WHETHER OR
NOT YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER IS INDICATED
BELOW THE KTM LOGO ON THE TYPE LABEL OF THE MUFFLER. ONLY "HGS KAT"
MUFFLERS ARE EQUIPPED WITH CATALYTIC CONVERTERS.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN
FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING.
BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE
ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN
THE EYES, SEEK A DOCTOR’S ADVICE IMMEDIATELY.
Fuel expands when its temperature rises. Therefore do not fill the tank to
the top (see fig.).
4
1
1
2
3
5
6
7
35 mm

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7
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the
carburetor.
ON When using the motorcycle, the twist grip must be set to the ON
position. Now fuel may flow to carburetor. In this position the tank
empties down to the fuel reserve of approx. 2.5 liters.
RES The reserve, approximately 2.5 liters, cannot be tapped until the twist
grip is turned to the RES position. Fill the tank as soon as possible and
remember to turn the twist grip back to the ON position so that you
will have backup fuel next time, too.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE
ENGINE.
Shift lever
The shift lever is mounted on the left side of the engine. The position of
the gears is shown in the illustration. Neutral, or the idle speed, is located
between first and second gear.
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can
be swivelled.

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 pedal
The foot brake pedal is located in front of the right footrest. Its basic
position can be adjusted to your seat position (see maintenance work).

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 LOOKED OVER BY A KTM DEALER.
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
OFF ON RES
2,3,4,5
1
N

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8
Compression damping of fork
The compression damping mechanism is built into the left fork tube. It only
regulates the degree of damping during compression.
By using the knob 1(COM), the degree of damping of the compression
can be adjusted. Turn the knob clockwise to increase damping, turn it
counterclockwise to reduce damping during compression.
BASIC SETTING
– turn rotary knob clockwise as far as it will go
– turn it back counter-clockwise by as many clicks as are specified for the
relevant type of fork
– 918S757..........12 clicks (400/640 LC4/Supermoto)
– 918S776..........12 clicks (400/640 LC4R)
Rebound damping of fork
The rebound damping mechanism is built into the right fork tube. It only
regulates the degree of damping during rebounding.
By using the knob 2(REB), the degree of damping of the rebound can be
adjusted. Turn the knob clockwise to increase damping, turn it counter-
clockwise to reduce damping during rebounding.
BASIC SETTING
– turn rotary knob clockwise as far as it will go
– turn it back counter-clockwise by as many clicks as are specified for the
relevant type of fork
– 918S757..........12 clicks (400/640 LC4/Supermoto)
– 918S776..........12 clicks (400/640 LC4R)
Compression damping of shock absorber
With the knob 3the degree of damping of the compression can be adjus-
ted to 7 positions. Turn the knob counterclockwise to increase damping,
turn it clockwise to reduce damping during compression.
BASIC SETTING
118S701 ..............position 3 (400/640 LC4/Supermoto)
118Q784.............position 3 (400/640 LC4R)
Rebound damping of shock absorber
With the setting wheel 4the degree of damping of the rebound can be
adjusted to 11 positions. Turn the knob to the left side to increase damping,
turn it to the right side to reduce damping during rebounding.
BASIC SETTING:
118S701 ..............position 5 (400/640 LC4/Supermoto)
118Q784.............position 4 (400/640 LC4R)

WARNING

–NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS.
–T
HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED
NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY
MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Baggage carrier
The baggage carrier may be loaded with up to 10 kg. The two lateral hoops
serve as handles for the passenger
1
2
3
4

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9
– Adjust the hand brake lever and the foot brake pedal to the
most comfortable positions for you.
– Get used to handling the motorcycle on an empty car park,
before starting on a longer drive. Also try to drive as slowly
as possible and in standing position, to improve your feeling
for the vehicle.
– Do not drive along off-road tracks which go beyond your
ability and experience.
– Hold the handlebar with both hands and leave your feet on
the foot rests while driving.
–
Remove your foot from the foot brake pedal when you are
not braking. If the foot brake pedal is not released the brake
pads rub continuously and the braking system is
overheated.
– You may only be accompanied by a passenger if your
motorcycle is fitted and registered for such purposes. The
passenger must hold tight to the brackets or hold on to the
driver during the drive, with his feet on the passenger foot
rests.
– Do not make any alterations to the motorcycle and always
use ORIGINAL KTM SPARE PARTS. Spare parts from other
manufacturers can impair the safety of the motorcycle.
– Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be
secured as close as possible to the middle of the vehicle;
distribute the weight evenly between the front and rear
wheel. Never exceed the maximum permissible laden
weight and the axle weights. The maximum permissible
laden weight is made up of the following components:
– Motorcycle ready for operation and tank full
– Luggage
–
Driver and passenger with protective clothing and helmet.
– Pay attention to running in instructions.
Running in the LC4 models
Even finely machined surfaces of engine parts have rougher
surfaces than parts that slide on each other for a long time.
Therefore, every engine must be run in. For this reason, do not
demand maximum performance from the engine for the first
100 kilometers. The vehicle must be run in at low, changing
performance level for the first 1000 KM (620 miles). The
engine speed of 4800 r.p.m. must not be exceeded during the
first 1000 kilometers (620 miles). During this break-in time,
you should ride your motorcycle in different conditions. The
following table shows you the maximum velocity values in the
different gears at 4800 r.p.m. as based on the rear wheel
transmission ratio of your motorcycle.
Exceeding the above listed rotations as well as pushing high
rpm when the engine is cold will have an adverse effect on the
life of your engine.
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 MINE-
RAL OIL FORMULA. THIS ALSO APPLIES IF THE ENGINE HAS BEEN REPAIRED.
Check the following before each start
When you start off, the motorcycle must be in a perfect tech-
nical condition. For safety reasons, you should make a habit of
performing an overall check of your motorcycle before each
start.
The following checks should be performed:
1 CHECK THE OIL LEVEL
Insufficient oil results in premature wear and consequently
to engine damage.
2 FUEL
Check that there is sufficient fuel in the tank; when closing
the filler cap.
3 CHAIN
A loose chain can fall off; an extremely worn chain can tear,
and insufficient lubrication can result in unnecessary wear to
the chain and rear sprockets.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must
be replaced. The tread depth must comply with the legal
regulations. Also check the air pressure. Insufficient tread
and incorrect air pressure reduce the driving performance.
5 BRAKES
Check correct functioning of the braking system. Check for
sufficient brake fluid in the reservoir. The reservoirs have
been designed in such a way that brake fluid does not need
to be refilled even when the brake pads are worn. If the
level of brake fluid falls below the minimum value, this indi-
cates a leak in the braking system or completely worn out
brake pads. Arrange for the braking system to be checked
by a KTM specialist garage, as complete failure of the
braking system can be expected.
Also check the state of the brake hoses and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake pedal.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING LIQUID
Check the level of cooling liquid when the engine is cold.
8 ELECTRICAL SYSTEM
Check headlight, parking light, tail light, brake light,
flashers, indicator lamps and horn for faultless operation.
9 LUGGAGE
If you are taking luggage with you, check that this is
securely fastened.

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
COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS
EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED
SUITABLE PROTECTIVE CLOTHING.
–A
LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
–D
O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–O
NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR
EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF
THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT
DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING
PROPERTIES.
–T
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.
Instructions for initial operation
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– Read the entire manual carefully before your first drive.
– Familiarize yourself with the operating elements.
DRIVING INSTRUCTIONS
400 LC4 640 LC4 Supermoto
15:45 t 16:42 t 17:40 t
1st 30 (19) 35 (22) 35 (22)
2nd 45 (30) 50 (32) 55 ( 35)
3rd 60 (38) 70 (44) 75 (47)
4th 75 (47) 90 (57) 90 (57)
5th 85 (54) 100 (63) 105 (66)
gear
ratio

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10
Starting when the engine is cold
1 Open the fuel tap 1
2 Switch on ignition (turn ignition key 2into position ).
3 Switch on emergency OFF switch 3(symbol must be visible).
4 Switch transmission to idle (green indicator lamp N4lights up).
5 Operate cold starting device (choke) 5.
6 Do not accelerate; operate starter button 6.
7 If the engine starts, push the choke lever back a little bit, as soon as the
engine runs unevenly.
8 Lift motorcycle off center stand.

WARNING

– T O AVOID INJURIES
, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE
KICKSTARTER
.
–DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
–M
AXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST
5 SECONDS BEFORE TRYING AGAIN.
–D
ON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN
COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED
CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP
BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM.
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STAR-
TER 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 (ignition lock in position ).
– 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 „Trouble-
shooting“ 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.
Starting when the engine is warm or hot
1 Open the fuel tap 1
2 Switch on ignition (turn ignition key 2into position ).
3 Switch on emergency OFF switch (symbol must be visible).
4 Switch transmission to idle (green indicator lamp N 4lights up).
5 Do not accelerate; operate starter button 6.
6 Lift motorcycle off center stand or swing up side stand, respectively.
What to do when the engine is „flooded”
The throttle must be fully opened when starting. If necessary change
ignition plug.
Kickstart instructions
Start as described above, then push the kickstarter hard ALL THE WAY.

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.
1
2
4
6
3
5

ENGLISH
11
Starting off
Pull the clutch lever. Put the engine into first gear, slowly
release the clutch lever and open throttle at the same time.

WARNING

–B EFORE YOU START OFF , CHECK THAT THE MAIN STAND HAS BEEN
SWUNG UP FULLY
. I F THE STAND DRAGS ON THE GROUND
, THE
MOTORCYCLE CAN GO OUT OF CONTROL
.
–ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption.
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to
NEUTRAL.

WARNING

–O
BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING
TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE.
–A
DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–DRIVE CAREFULLY ON UNKNOWN ROADS
–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.
–R
EPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY
OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR
GOGGLES, YOU WILL BE PRACTICALLY BLIND.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
!
CAUTION
!
–H
IGH 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 OPERA-
TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE
VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE
MOTORCYCLE CAN EASILY GET OUT OF CONTROL.
–L
ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN
LEAD TO ENGINE DAMAGE.
–IF THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE
YOU ARE DRIVING, THIS INDICATES COOLING SYSTEM TROUBLE.
IMMEDIATELY STOP AND TURN OFF THE ENGINE. DRIVING WITH THE
WARNING LAMP ON WILL CAUSE ENGINE DAMAGE.
– PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY,
SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE. -
CAUTION SCALDING HAZARD! - AND CHECK THE COOLING
LIQUID LEVEL.
– DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COO-
LING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS AS
SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.
!
CAUTION
!
–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 IMMEDIA-
TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM
DEALER.
Braking
Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving downhill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND
BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE
BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM
CAN FAIL.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To stop
the engine, switch off the ignition. Turn the fuel tap to the
OFF position, park on an area where the ground is firm, and
lock the motorcycle.

WARNING

–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
–
M OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING
. T HE ENGINE RADIATORS , EXHAUST , EXHAUST SYSTEM , BRAKE
DISCS
, AND SHOCK ABSORBERS CAN BECOME VERY HOT
. D O NOT
TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE
, AND
TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH
IT AND GET BURNED
– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE
HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE
MATERIALS.
!
CAUTION
!
–C
LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE
CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE.
–A
LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR
MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED
PERSONS.

ENGLISH
12
NOTE REGARDING THE CENTER STAND:
We advise the following procedure to place the motorcycle on the center
stand as effortlessly as possible:
a) press main stand to ground using foot
b) swing out kickstarter and pull motorcycle backwards at an angle as illust-
rated (see illustration).
Make sure that the ground is solid and that your motorcycle is standing
securely.
INFORMATION ABOUT THE SIDE STAND:
Use your foot to push the side stand forward as far as possible, and lean
your motorcycle to the side. Make sure that your motorcycle is standing
safely on solid ground. Just in case, you can also put in a gear.
Motorcycles that have a side stand are provided with a safety starting
system. If the side stand has been swung out from the motorcycle, the
engine can only be started if the transmission has been switched to idle or if
the clutch lever has been pulled in.
If you put in a gear with the side stand in its swung-out position, and if you
let go of the clutch lever, the engine will stop.
!
CAUTION
!
THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY. IF YOU
ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDITIONAL LOAD ONTO THE SIDE
STAND, YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME, AND YOUR
MOTORBIKE MAY FALL OVER.

ENGLISH
13
Check engine oil level 
Change engine oil 
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil 
Change oil filter insert 
Change fine screen filter (screwed filter) at front pipe (of the frame) 
Check oil lines for leakage and proper instalment without kinks 
Check valve clearance 
Clean spark plug and adjust electrode gap 
Change spark plug after 10 000 kilometers (6 200 miles)
Drain and clean carburetor float chamber 
Adjust idling 
Check all air supply and ventilation hoses of of the engine and of the carburetor for kinks 
Clean air filter and air filter box 
Check sprockets, chain guides and chain for wear 
Clean and lube chain  
Check chain tension 
Check cooling liquid level 
Check quality of antifreezer 
Check cooling system for leaks – visual check 
Check exhaust system for leakage 
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 free play and easy operation of foot brake pedal 
Check adjustment and function of telescopic fork 
Check telescopic fork for leaks 
Loosen bleeder screws at fork legs (overpressure) 
Change telescopic fork oil 
Perform a full maintenance job for the telescopic fork 
Clean dust scrabber of telescopic fork 
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 
Service the shock absorber 
Grease nipple of the Pro Lever suspension system 
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it 
Service swingarm pivot 
Check spoke tension and join 
Check wheel bearings for clearance 
Check shock absorber rubbers on the rear 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, battery and connections 
Check adjustment of headlight 
Spray ignition lock, emergency off switch, and light switch with contact spray 
Check all screws, nuts and hose clamps for proper tightness 
Grease or lube all pivot points and sliding points 
PERIODIC MAINTENANCE SCHEDULE
before each start after washing 1st service, after 500 km (300 miles)
after 5000 km (3000 miles) or once a year
at least once a year
KTM
rider
KTM
dealer
IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM
(3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE
400/640 LC4 ’99
400/640 LC4R’99
620 LC4 Comp. ’99
Supermoto ‘99
10. 98

ENGLISH
14

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST KNOW-
LEDGE. FOR YOUR OWN SAFETY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER
!
CAUTION
!
–W
HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS,
CARBURETOR, ELECTRIC CONNECTORS ETC.
–W
HEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IFTHE
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.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–DISPOSE OF OIL, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS.
–U
NDER 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.
Tool set
The tool set 1is located in the tool box under the right side cover.
Removing the seat
Remove the collar screws 2from the underside of the fender. Lift the rear
of the seat, pull backwards, and unhook it from the oval-head screw 3.
To mount the seat hook it into the oval head screw, lower the rear part of
the seat and push the whole seat forwards. If necessary push the middle of
the seat slightly down to let the retaining bracket 4engage with the seat.
Finally fasten the seat with the corresponding screw.
MAINTENANCE WORK ON CHASSIS AND ENGINE
1
2
2
4
3

ENGLISH
15
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 1of the top triple clamp and turn steering stem bolt clockwise 2
until there is no more play. Don’t 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).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTOR-
CYCLE 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 BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
At least once a year, the steering head bearings should be greased.
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 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 4changes the spring preload by
approximately 1,75 mm (0,07 in).
Loosen the locking ring 3with the hook wrench from the tool set. Change
the spring preload with the adjusting ring 4and retighten the locking ring.
BASIC SETTING – SPRING PRELOAD
A = 23 mm (0,9 in)
Lubricating the shock absorber linkage
The bearings in the rocker arm must be greased (Shell Advance Grease) in
regular intervals. For this purpose, a grease nipple 5is mounted on the
rocker arm.
!
CAUTION
!
AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALLY IMPORTANT TO
GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.
A
2
1
3
4
5

ENGLISH
16
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.

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.
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
illustration)
– Now, the distance Abetween chain and swingarm should be 0 mm. The
upper part of the chain Bmust be tight (see illustration).
– Correct chain tension, if necessary!

WARNING

–IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER TRANSMIS-
SION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL BEARINGS) WILL BE
SUBJECTED TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN
CHAIN BREAKAGE.
–T
OO 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.
–I
N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
– Loosen collar nut 1, loosen counter nuts 2, and turn right and left
adjusting screws 3equally far. Tighten counter nuts 2.
– Before tightening the wheel spindle, verify that the chain adjusters 4are
sitting close to the adjusting screws and that the rear wheel has been
aligned with the front wheel.
– Tighten collar nut 1with 80 Nm (60 ft.lb).

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. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
Chain maintenance
For long chain life, good maintenance is very important. O-ring chains
require only modest maintenance. The best way is to use lots of water, but
never use brushes or solvents. 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 TIRE OR THE BRAKE DISK, EITHERWISE
THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY
REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL.
!
CAUTION
!
WHEN MOUNTING THE CHAIN JOINT, THE CLOSED SIDE OF THE SAFETY DEVICE MUST
POINT IN RUNNING DIRECTION.
Also check sprockets and chain guides for wear, and replace if necessary.
✓
A
B
15:45
16:38
17:40
A = 0 mm
16:42
30mm
3
4
2
1
4
3
2
min. 2,5 mm

ENGLISH
17
Chain wear
In order to check the chain wear, regard the following instructions:
Shift the gear into idling and pull the upper chain strand with approx. 10-15
kilogramm (33 lb) upwards (see figure). Now one can measure a space of
18 chain reels at the lower chain strand. The chain should be replaced at the
latest when a space 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
chains wear faster if used on old used sprockets.
General informations about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series “float“. This means that the brake calipers
are not solidly attached to the caliper support. Thus, the brake pads are
always in optimum contact with the brake disc.
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 application of these motorcycles.
It is only for competitive racing in extremely dirty conditions (e.g., water in
combination with sand and mud) that we recommend brake pads that have
sintered linings. However, take notice of the fact that brake pads with sinte-
red linings have not been type-coded! Besides, they may cause greater wear
on the brake discs.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not
necessary to top up the brake fluid. If the brake fluid level drops below the
minimum either the brake system has a leak or the brake pads are
completely worn down.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake systems with Shell Advance Brake DOT 5.1 brake fluid,
one of the best brake 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 not have any DOT 5.1 for refilling, you may use
DOT 4 brake fluid. However, you should replace it as soon as possible
by DOT 5.1.
Adjusting of free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjusting
screw 1. In this way, the position of the point of pressure (i.e., the
resistance you feel on 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 GREA-
TER RESISTANCE 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
DOT
5.1
DOT
5
✓✕
min. 3 mm
1

Checking of brake fluid level - front brake
The brake fluid reservoir is linked with the hand brake cylinder at the
handlebar and the reservoir is provided with an inspection glass. With the
reservoir in a horizontal position, the brake fluid level should not go below
middle of the glass.

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN
AUTHORIZED KTM DEALER IMMEDIATELY.
Refilling the front brake fluid reservoir*
Loosen screws 1and remove lid 2and membrane 3.
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0,2 in) below the rim with brake fluid DOT 5.1 (Shell
Advance Brake DOT 5.1). Replace membrane and lid, tighten screws. Rinse
off spilled or overflowing brake fluid with water.

WARNING

–N
EVER 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.
–S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–B
RAKE 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
!
–D
ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT
REMOVER.
–U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
Checking the front brake pads
The brake pads can be inspected from below. The linings must 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 AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE
DISC, IMPAIRING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Changing the basic position of the foot brake pedal*
The basic position of the foot brake pedal can be altered by turning the stop
roller 4. The free play at the foot brake pedal must then be adjusted by
means of the piston rod 5.
Measured on the outside, the foot brake pedal must have 3-5 mm
(0,12–0,20 in) of free play, before the piston rod can move the piston in the
brake cylinder (to be recognised from the resistance on the foot
brake pedal).
!
CAUTION
!
IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM
WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE PADS.THE BRAKING SYSTEM
OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES.
ENGLISH
18
3-5mm
5 mm
min.
1 mm
1
2
3
4
5