KTM 625 LC4 SUPERCOMPETITION User guide

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

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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 MOTORCYCLE
IS NOT ROAD-SAFE ANYMORE.
Please insert the series numbers of your motorcycle in the boxes below
Chassis 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 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 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.
CONSUMER INFORMATION FOR AUSTRALIA ONLY
KTM S PORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATIONS , COLORS ,
MATERIALS , SERVICES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT
PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS
, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI -
TUTING THEM WITH OTHERS
. I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I NTHE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .
W
ESHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS .

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2
Introduction
We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this
opportunity to thank you for putting your trust in us; we will not let you down.
You are now owner of a sporty and modern motorcycle which you are bound to have a great time
with provided you care for it properly. Before going for a first ride on your motorbike, you should
read this Owner’s Handbook carefully, even if this takes some of your precious time, so as to
familiarize yourself with how your motorbike is to be operated and which features it offers you.
Only by doing that you will learn how you can best tune your motorcycle to your needs and how
you can avoid bodily injuries. In addition, this Owner’s Handbook contains invaluable informa-
tion about motorcycle maintenance. At the time of printing, this User's Guide corresponded to the
latest state of this model family. It is, however, possible that we may have made slight modificati-
ons in the meantime due to development in our motorcycle design.
The Owner’s Handbook is an essential part of the motorbike and should - when the bike is sold -
be handed over to the new owner.
Many motorcyclists have a good technical knowledge of motorcycle mechanics; if this is true 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 have a professional KTM dealer perform those steps marked by *found in the chapter entitled
“Maintenance Work on Chassis and Engine” of this manual.
For your own safety use only KTM-approved parts and accessories. KTM is not liable for damage
that arises in connection with the use of other products.
Take special care to follow the recommended run in, inspection, and maintenance
intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Be sure to
have any maintenance jobs performed by an authorized KTM dealer.
Address your special requests to an authorized KTM dealer who, should the need arise, will be
supported by the KTM importer.
Please do not forget to wear your helmet, eye protection, and protective clothing when going for
a ride. KTM riders are responsible riders! We wish you a lot of fun when driving !
Attachments: 1 spare parts manual chassis
1 spare parts manual engine
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
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.

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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
Hand brake lever..............................................................4
Indicator lamps.................................................................5
Electronic speedometer.....................................................5
Combination switch..........................................................5
Flasher switch...................................................................6
Filler cap...........................................................................6
Fuel tap............................................................................6
Choke ..............................................................................6
Shift lever .........................................................................6
Kickstarter ........................................................................7
Foot brake pedal ..............................................................7
Handlebar lock .................................................................7
Compression damping of fork ..........................................7
Rebound damping of fork ................................................7
Compression damping of shock absorber .........................8
Rebound damping of shock absorber ...............................8
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE.....................................................................9
DRIVING INSTRUCTIONS ..................................................10
PERIODIC MAINTENANCE-SCHEDULE ..............................13
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........15
Removal of seat..............................................................15
Tool set ..........................................................................15
Breather plugs front fork ................................................16
Cleaning the dust sleeves of the telescopic fork ..............16
Check and adjust steering head bearing .........................16
How to change the handlebar position...........................17
Check/set distance of the magnetic sensor .....................17
Changing the spring preloading of the shock absorber ...17
Checking rubber ring on the WP rear shock absorber .....18
Lubricate rear suspension linkage ...................................18
Checking chain tension...................................................18
Correct chain tension......................................................18
Chain maintenance.........................................................19
Page
Chain wear.....................................................................19
General informations 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
Replacing front brake pads .............................................21
Changing the basic position of the brake pedal ..............22
Checking the rear brake fluid level..................................22
Refilling the rear brake fluid reservoir .............................22
Checking the rear brake pads .........................................22
Replacing the rear brake pads.........................................23
Dismounting and mounting the front wheel...................23
Dismounting and mounting the rear wheel.....................24
Checking the shock absorption rubbers in the rear hub ..25
Tires, air pressure............................................................25
Checking spoke tension..................................................25
Cooling system...............................................................26
Checking the coolant level..............................................26
Cleaning air filter ............................................................27
Exhaust system...............................................................27
Draining the float chamber of the carburetor..................27
Carburetor – Adjust idling...............................................28
Adjusting the mixture control screw ...............................28
Check float level.............................................................28
Adjusting the throttle cable ............................................29
Adjusting the clutch cable...............................................29
Checking the adjustment of the hand decompression cable .....29
Engine oil .......................................................................30
Checking the engine oil level..........................................30
Oil circuit........................................................................30
Changing the engine oil .................................................30
Changing and bleeding the microfilter............................31
Changing oil filter...........................................................31
TROUBLE SHOOTING........................................................32
CLEANING..........................................................................34
CONSERVATION FOR WINTER OPERATION ....................34
STORAGE ...........................................................................34
Re-initation after time of storage....................................34
TECHNICAL SPECIFICATIONS - ENGINE ...........................35
TECHNICAL SPECIFICATIONS - CHASSIS...........................37
WIRING DIAGRAMME ..........................................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 handlebar. When
engine is cold, there should always be a play of 1–3 mm (0,04–0,1 in) at
this lever (measured at outer edge).
Hand decompression lever
The hand decompression lever 2is only used in two special cases:
a) When the engine stalled.
When you then start the engine, you may feel a hard resistance on the
kickstarter, because the automatic decompressor cannot lock into place.
If this happens, pull the hand decompression lever and use the kickstar-
ter. Afterwards you can start the engine normally again.
b) When you want to push-start the motorcycle.
While pushing, pull the decompression lever to make it easier to get the
engine going.
Hand brake lever
The hand brake lever is mounted on the right side of the handle bar and
actuates the front wheel brake.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1-3 mm
1
2

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5
Indicator lamp
The green control lamp 1flashes when the indicator is working in
the same rhythm as the flashing indicator.
The blue control lamp 2lights up when the high beam is on.
Electronic speedometer
The electronic speedometer display is activated as soon as the engine is
switched on and the motorcycle starts to move.
The engine must be started in order for the speedometer to be supplied
with electricity from the generator. The display is not activated until the
front wheel has made 1 revolution (impulse for speedometer).
TEST
All of the display elements will light up for 1 second for the function test.
WS (wheel size)
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 traveled.
The information will disappear in the display when the front wheel stops
turning for 1 minute.
NOTE:
A Tripmaster switch (part no 583.14.069.244) is available as an accessory
and enhances the electronic speedometer by providing the following
functions:
2x Tripmaster
2x chronometer for the lap time
Average speed
Maximum speed
Service hours
Clock
Display in miles
Combination switch
The light switch has 3 switch positions.
A= Light off
B= Low beam light
C= High beam light
The red short circuit button 3serves to switch off the engine. Leave the
switch pressed, until the engine stops. With the button 4the horn will
sound.
A
B
C
4
3
1
2

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6
Flasher switch
The flasher switch is a separate unit and is mounted on the left portion of
the handlebar.
The wire harness is designed in a way that whenever you want to use your
bike off-road, you can dismount the entire turn indicator system without
affecting the function of the remaining electrical system.
Flasher left
Flasher right
Filler cap
To open filler cap: Turn the filler cap counter-clockwise.
To close filler cap: Screw on the filler cap clockwise.
Install tank breather hose 1without kinks.
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carburetor.
ON When using the motorcycle, the rotating handle must be set to the
ON position. Now fuel may flow to carburetor. In this position the
tank empties down to the fuel reserve of approx. 1,5 liters.
RES The 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 ON
position so that you will have backup fuel next time, too.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IFTHE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
Choke
If you pull the choke button 2out as far as possible, a bore in the carbure-
tor will be unblocked through which the engine may take in additional fuel.
The result is a „fat“ fuel-air mixture of the type needed for cold starts.
To deactivate the choke, push the choke button back into its basic position.
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 position is located
between first and second gear.
1
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
RES
ON
OFF
2,3,4,5
1
N
2

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7
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can
be swivelled.
Foot brake pedal
The foot brake pedal is located in front of the right foot rest. Its basic
position can be adjusted to your seat position (see maintenance work).
Handlebar lock
The handlebar can be locked by means of the lock located on the control
head. Fully turn handlebar to right to lock, insert key, turn to left, press in,
turn to right and withdraw.
!
CAUTION
!
NEVER LEAVE THE KEY INSERTED IN THE LOCK. IFYOU TURN THE STEERING TO THE LEFT
THE KEY COULD GET DAMAGED.
Compression damping of fork
The compression damping is to be set at the lower end of the fork tubes. It
only regulates the degree of damping during compression. 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 compression.
STANDARD ADJUSTMENT:
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
WP 0518W712 ................... 20 clicks (625 SC)
WP 0518W722.................... 14 clicks (625 SC SUPERMOTO)
Rebound damping of fork
Hydraulic rebound damping determines the reaction when the fork is re-
bound. By turning the knob 2,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.
STANDARD ADJUSTMENT:
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
WP 0518W712 ................... 12 clicks (625 SC)
WP 0518W722.................... 14 clicks (625 SC SUPERMOTO)
22
A1

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8
Compression damping of shock absorber
With the knob 1the degree of damping of the compression can be
adjusted. Turn the knob counterclockwise to increase damping, turn it
clockwise to reduce damping during rebounding.
STANDARD ADJUSTMENT:
WP 0118W714.................. position 3 (625 SC)
WP 0118W721.................. position 5 (625 SC SUPERMOTO)
Rebound damping of shock absorber
With the setting wheel 2the degree of damping of the rebound can be
adjusted. Turn the knob to the left side to increase damping, turn it to the
right side to reduce damping during rebounding.
STANDARD ADJUSTMENT:
WP 0118W714.................. position 5 (625 SC)
WP 0118W721.................. position 7 (625 SC SUPERMOTO)
1
2

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9
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE
Instructions for initial operation
–Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
–Read these operating instructions carefully before your first
ride.
–Familiarize yourself with the operating elements.
–Adjust the hand brake lever and foot brake lever to your
most comfortable position.
–Get used to handling the motorcycle on an empty parking
lot or open space, 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
abitily and experience.
–Hold the handlebars with both hands and leave your feet on
the foot rests while driving.
–
Remove your foot from the foot brake lever when you
are not braking. If the foot brake lever is not released the
brake pads rub continuously and the braking system is
overheated.
–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; dis-
tribute 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 with protective clothing and helmet.
–Pay attention to running-in procedure.
Running in the LC4 models
Even very precisely machined sections of engine components
have rougher surfaces than components which have been
sliding against one another for quite some time. Therefore,
every engine needs to be broken in. For this reason, during its
first 1000 kilometers (620 miles) the engine must not be
revved up to its performance limits. 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 (roads, easy off-road
terrain). 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.
NOTE:
DURING THE STAGE OF RUNNING THE ENGINE IN, THAT IS THE FIRST
1000 KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF A
MINERAL OIL FORMULA. THIS ALSO APPLIES IF THE ENGINE HAS BEEN
REPAIRED.

WARNING

–W
EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER
KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A
JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A
SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY
COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSI-
BLE. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE
CLOTHING.
–D
ONOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–A
LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
–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 VEHICLES DRIVING
PROPERTIES.
–T
HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY
WITH TIRES THAT HAVE THE SAME PROFILE TYPE.
–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.
–C
HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–D
RIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.
–RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR GOGG-
LES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION.
WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES,
THE OPERATOR WILL BE BLINDED.
–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE
ENGINE IS RUNNING.

WARNING

IMPORTANT INSTRUCTIONS FOR SUPER COMPETITION
MODELS:
–T
HESE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY -
NO ADDITIONAL PASSENGER ALLOWED!
–W
HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT
OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.
625 SC 625 SC SUPERMOTO
16:40 Z 17:38 Z
1. G 35 kmh 35 km/h
2. G 50 kmh 55 km/h
3. G 70 kmh 75 km/h
4. G 90 kmh 90 km/h
5. G 100 kmh 105 km/h
gear
ratio

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10
Check the following before each start
When you start, the motorcycle must be in perfect mechanical
condition. For safety reasons, you should make a habit of per-
forming an overall check of your motorcycle before each start.
The following checks should be performed:
1 CHECK 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, check that the tank venting hose is free of
kinks.
3 CHAIN
A loose chain can fall from the chain wheels; an extremely
worn chain can tear, and insufficient lubrication can result in
unnecessary wear of chain and chain wheels.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must be
replaced. The tread depth must comply with the legal regula-
tions. Also check the air pressure. Insufficient tread and incor-
rect air pressure 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 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, as complete failure of the braking
system can be avoided.
Also check the state of the brake hose and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake lever.
6 CABLES
Check correct setting and smooth operation of all control
cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
8 ELECTRICAL SYSTEM
Check correct operation of headlamps, tail-lights, brake
lights, indicators, control lamps and horn while the engine is
running.
9 LUGGAGE
If you are taking luggage with you, check that this is
securely fastened.
DRIVING INSTRUCTIONS
MAX
MIN

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11
Starting when the engine is cold
1Open the fuel tap 1
2Swing up the side stand or center stand.
3Put the gear in neutral
4Operate the choke 2
5Go to the left of your motorbike. DO NOT open the throttle, and briskly
kick the kickstarter ALL THE WAY.

WARNING

–I
FYOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY
MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICK-
STARTER, OR THE ENGINE MAY KICK BACK AND PUSH YOUR FOOT UPWARD WITH
GREAT VEHEMENCE.
–A
LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.
KICKING THE KICKSTARTER WITH LESS ENOUGH FORCE AND AN OPENED THROTTLE
INCREASE THE KICK-BACK HAZARD.
–D
ONOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DON’TRIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS
COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLIN-
DER, IT CAN CAUSE ENGINE DAMAGE.
Starting when the engine is warm
1 Open the fuel tap 1
2Swing up the side stand or center stand.
3Put the gear in neutral
4Leave the throttle 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 times and start the motor as described
above.
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

BEFORE YOU START, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG UP FULLY.
IFTHE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GET OUT OF CONTROL.
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear. Depending
on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close
throttle, at the same time pull clutch lever in 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 opening the throttle all the way, turn
throttle back to 3/4; the speed will not decreases but the engine will use less
fuel.
Only give as much throttle as the engine can handle. Through quick and
high reving of throttle, the fuel consumption increases. When 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.
2
1

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12
!
CAUTION
!
–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE.
–N
EVER PARK YOUR MOTORCYCLE IN FIRE HAZARDOUS PLACES DUE TO
DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.
NOTE REGARDING THE MAIN STAND:
We advise the following procedure to place the motorcycle on
the main stand as effortlessly as possible:
a) press main stand to ground using foot.
b) swing out kickstarter and pull at an angle toward the rear of
motorcycle (see illustration).
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.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION
SHOULD BE USED WHEN HANDLING GASOLINE. DONOT REFUEL THE
MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS
SWITCH OFF THE ENGINE BEFORE REFUELLING. BECAREFUL NOT TO SPILL
GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IFGASOLINE IS SWALLOWED OR SPLASHED IN
THE EYES, SEEK A DOCTOR’SADVICE IMMEDIATELY.
Fuel expands when its temperature rises. Therefore do not fill
the tank to the top (see fig.).

WARNING

–A
VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND
ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE
CONTROL OF YOUR MOTORCYCLE.
–W
HEN 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.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
–A
BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO
STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS
STABILITY.
!
CAUTION
!
–H
IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WERECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES TO WARM
UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE
TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS
SOON AS THE RADIATORS BECOME WARM.
–NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
ALOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE VALVES.
INADDITION, THE REAR WHEEL LOCKS 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 MOTOR DAMAGE.
–I
FANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT
THE ENGINE FASTENING BOLTS ARE TIGHT.
–I
NTHE 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 care, blocking
wheels can cause you to skid or fall. Also change down to
lower gears depending on your speed.
When driving down hill, 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

–IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES
THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS,
HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE
BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN.
–R
IDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE
BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.
–DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS.
–W
HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER
AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE
WEAKER THE BREAKING EFFECT. INEXTREME 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 or pull the short circuit but-
ton when the engine is idling, until the engine stops. Turn the
fuel tap to the OFF position, park on an area with firm ground,
and lock the motorcycle.

WARNING

–ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL
SURFACE.
–M
OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DONOT 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.
35 mm

ENGLISH
13
PERIODIC MAINTENANCE SCHEDULE 2002
after / every
2500 km
or
25 hours
1. Service after
1000 km
or
10 hours
after / every
5000 km
or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM.
M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER !
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and micro-filter ●●●
Clean oil screens and magnet of drain plug ●●
Check oil lines for damage and kink-less arrangement ●●
Check and adjust spark plug, replace every 10,000 km ●
Check and adjust valve clearance ●●
Check engine fastening screws for tight fit ●●
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 exhaust system for leaks and suspension ●●
Check actuating cables for damage, smooth operation, and kink-less ●●
arrangement, adjust and lubricate
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, ●●
tell-tale lamps, 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/footbrake levers ●●
Check screws of brake system for tight fit ●●
Check suspension strut and fork for leaks and proper function ●●
Check O-ring of suspension strut for wear ●
Clean 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 join ●●
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 ●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance ●
Perform complete suspension strut maintenance ●
Perform complete reversing lever maintenance ●
Replace glass-fiber yarn packing of main silencer ●
Clean and lubricate steering-head bearing and sealing elements ●
Clean and adjust the carburetor ●
Treat the electrical contacts and switches with contact spray ●
Change brake fluid ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURATOR
ENGINE
625 SC
625 SC SUPERMOTO
every 2 years
or 20000 km
at least
once a year
every 2500 km
or 25 hours

ENGLISH
14
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level ●
Check brake fluid level ●
Check brake pads for wear ●
Check lighting system for proper operation ●
Check horn for proper operation ●
Lubricate and adjust actuating cables and nipples ●
Bleed fork legs in regular intervals ●
Remove and clean dust sleeves in regular 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 ●
Verify smooth operation of all controls ●
Check brake performance ●●
Treat exposed metal components (except for the braking and exhaust ●
systems) with wax-based anti-corrosion agents
Treat steering lock and light switch with contact spray ●
Check all screws, nuts, and hose clamps for tight fit ●
once a yearfor cross
country use
after every
cleaning
before each
start

ENGLISH
15
2
3
1

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST
KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER. AT KTM YOUR
MOTORCYCLE WILL RECIEVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS.
!
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.
–WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT
THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL DOWN, BE AWARE OF ANY LEAKING FUEL FROM THE CARBURETOR OR
FUEL TANK
–D
ONOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING
LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–R
EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.
–UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN 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 SPECIFICATI-
ONS - FASTENING TORQUES ON PAGE 36/37.
Removal of seat
By using the quick-release fastener 1, the seat can be removed without
using tools. Turn the quick-release fastener about 180° counter clockwise
and lift up the rear of the seat. Pull the seat backwards and unhook it from
the front fastener screw 2.
When installing the seat, be sure to insert the rear portion of the seat into
the metal clasp 3.
Tool set
The tool set 4is accommodated in the tool compartment behind the seat.
MAINTENANCE WORK ON CHASSIS AND ENGINE
1
4

ENGLISH
16
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs 1a few turns in order to relieve excess pressure from the inside 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 mainten-
ance service.
!
CAUTION
!
EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF
YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE
HAVING THE SEALS REPLACED.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 2are 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. Then, push dust-protection bellows
into the outer tubes by hand.
Check and adjust steering head bearing *
Check steering head bearing for play periodically. 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 pinch
bolts 3of the top triple clamp and turn steering stem bolt 4clockwise
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 tap
on the triple clamp to release tension. Retight the five pinch bolts with
20 Nm (15 ft.lbs).

WARNING

IFTHE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-
CLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL.
!
CAUTION
!
IFYOU DRIVE WITH PLAY OF 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 smeared with
waterproof grease (Shell Advance Grease).
2
3
4
3
1

ENGLISH
17
1
2
3
4
15 mm
3,5 mm
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar to the position that is the most convenient for you. The upper tri-
ple clamp 1includes 2 bores arranged at a distance of 15 mm (0,6 in) from
one another. The bores at the handlebar support 2are offset from the cen-
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws 3of the handlebar clamps and screws 4
of the handlebar support. Position handlebar support, and tighten screws 4
to 40 Nm (30 ft.lbs). Mount handlebar and handlebar clamps, and tighten
screws 3to 20 Nm (15 ft.lbs). The gap between handlebar support and
handlebar clamps is to be of equal size in the front and in the rear.
Check/set distance of the magnetic sensor
The distance between magnet and sensor 5must be 2-4 mm, otherwise
malfunctions on the speedometer might occur.
This distance can be corrected by screwing in or off the sensor 5.
Changing the spring preloading of the shock absorber
KTM sets the shock absorber for a driver with a weight of approximately
75 kg (165 lb). If the weight of the driver is more or less than 75 kg (165
lb), you should change the spring preloading Aaccordingly. This is easily
done.
NOTE:
–Before changing the spring preload note the basic setting, e.g. how
many threads are visible above the adjusting ring.
–One rotation of the adjusting ring 6changes the spring pretension by
approximately 1,75 mm (0,07 in).
Loosen the locking ring 7with the hook spanner from the tool set. Change
the spring preload with the adjusting ring 6and re-tighten the locking ring.
BASIC SETTING – SPRING PRELOAD:
WP 0118W714 ............... A = 23 mm (625 SC)
WP 0118W721 ............... A = 15 mm (625 SC SUPERMOTO)
A
6
7
5

ENGLISH
18
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 ab-
sorbing function.
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 NITRO-
GEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE
WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Lubricate rear suspension linkage
The bearings in the link lever must be greased in regular intervals. For this
purpose, a lubricating nipple 1is mounted on the link lever.
!
CAUTION
!
AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALY IMPORTANT TO GREASE
THE LUBRICATING NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.
Checking chain tension
For checking, put the motorcycle on its main stand or jack it up on its frame
so that the rear wheel is relieved of any load.
Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sli-
ding component until the upper part of the chain is tensioned (see
illustration)
Now, the distance Abetween chain and swingarm should be 0 mm respec-
tively 5 mm (0,2 in) (depending on final drive ratio). The upper part of the
chain Bmust be tight (see illustration).
Correct chain tension, if necessary!

WARNING

–IFCHAIN TENSION IS TOO HIGH, PARTS WITHIN THE SECONDARY TRANSMISSION
(CHAIN, SPROCKETS, DRIVE ASSEMBLY 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 SPROCKETS. IFTHIS HAPPENS, THE CHAIN COULD ALSO BLOCK THE
REAR WHEEL OR DAMAGE THE ENGINE.
–I
NEITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
Loosen collar nut 2, loosen lock nuts 3, and turn right and left
adjusting screws 4equally far. Tighten lock nuts 3.
Before tightening the collar nut, verify that the chain adjusters 5are
sitting close to the adjusting screws and that the rear wheel has been
aligned with the front wheel.
Tighten collar nut 2with 80 Nm (59 ft.lb).

WARNING

IFYOU DON’THAPPEN 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.
B
16:48
16:40 A = 0mm
16:45
17:38
30mm
A
min. 2,5 mm
2
3
4
3
5
5
4
1

ENGLISH
19
✓
15 KG
max. 272 mm
1 2 3 16 17 18
Chain maintenance
For long chain life, good maintenance is very important. X-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 X-ring chain spray (Shell Advance Bio Chain).

WARNING

NOLUBRICATION 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.
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 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 pla-
ces 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 information 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. Secure the screws of the
caliper support with Loctite 243 and tighten to 25 Nm (19 ft.lb).