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KTM 625 LC4 SUPERCOMPETITION Owner's Handbook Manual
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KTM 625 LC4 SUPERCOMPETITION Owner's Handbook Manual

2002
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Summary of Contents for KTM 625 LC4 SUPERCOMPETITION

  • Page 2 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT...
  • Page 3 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.

  • Page 4: Table Of Contents

    Page SERIAL NUMBER LOCATIONS ..........4 Chain wear..............19 Chassis number ..............4 General informations about KTM disc brakes....19 Engine number, engine type..........4 Adjusting of free travel at the hand brake lever ....20 OPERATION INSTRUMENTS ..........4 Checking brake fluid level - front brake ......20 Clutch lever ..............4...

  • Page 5: Serial Number Locations

    SERIAL NUMBER LOCATIONS 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.

  • Page 6: Indicator Lamps

    Indicator lamp The green control lamp flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp lights 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.

  • Page 7: Flasher Switch

    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.

  • Page 8: Kickstarter

    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.

  • Page 9: Compression Damping Of Shock Absorber

    Compression damping of shock absorber With the knob the 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....

  • Page 10: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE LEVER OF VEHICLE jobs (see Customer Service Manual). DRIVERS ALWAYS WEAR A HELMET...

  • Page 11: Driving Instructions

    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.
  • Page 12 Starting when the engine is cold 1 Open the fuel tap 2 Swing up the side stand or center stand. 3 Put the gear in neutral 4 Operate the choke 5 Go to the left of your motorbike. DO NOT open the throttle, and briskly kick the kickstarter ALL THE WAY.

  • Page 13: Stopping And Parking

    WARNING CAUTION – A – C VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE THERWISE THE ON WET OR SLIPPERY GROUND THERWISE YOU MIGHT EASILY LOSE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE –...

  • Page 14: Periodic Maintenance-Schedule

    625 SC PERIODIC MAINTENANCE SCHEDULE 2002 625 SC SUPERMOTO 1. Service after after / every after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year ●...
  • Page 15 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use ● Check oil level ● Check brake fluid level ● Check brake pads for wear ●...

  • Page 16: Maintenance Work On Chassis And Engine

    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.

  • Page 17: Breather Plugs Front Fork

    Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs a 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.

  • Page 18: How To Change The Handlebar Position

    This distance can be corrected by screwing in or off the sensor 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 accordingly.

  • Page 19: Checking Rubber Ring On The Wp Rear Shock Absorber

    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 min. 2,5 mm the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. CAUTION...

  • Page 20: Chain Maintenance

    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.

  • Page 21: Adjusting Of Free Travel At The Hand Brake Lever

    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.

  • Page 22: Refilling The Front Brake Fluid Reservoir

    Refilling the front brake fluid reservoir * When the brake fluid falls to the middle of the inspection glass, new brake fluid has to be added. Loosen screws and remove lid and membrane Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0,2 in) below the rim with clean brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1).

  • Page 23: Changing The Basic Position Of The Brake Pedal

    Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set.

  • Page 24: Replacing The Rear Brake Pads

    Replacing the rear brake pads * Press brake caliper in direction of chain wheel for the brake piston to reach its basic position. Remove safety device , knock out the guide pin from the brake caliper with a drift towards the chain wheel and remove brake pads.

  • Page 25: Dismounting And Mounting The Rear Wheel

    Dismounting and mounting the front wheel (625 SC SUPERMOTO) The front wheel of the SC SUPERMOTO is essentially removed in the same manner as the front wheel of the 625 SC. However, the brake caliper has first to be removed. To remove the front brake caliper, remove both screws and pull the caliper backwards from the brake disc.

  • Page 26: Checking The Shock Absorption Rubbers In The Rear Hub

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING –...

  • Page 27: Cooling System

    Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the coolant is also pumped through both aluminum radiators.

  • Page 28: Cleaning Air Filter

    To replace the rear glass fiber yarn pack, drill the rivets open and remove the rear cap NOTE: Always renew the O-rings Glass fiber yarn packs are available in your KTM store. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING AVOID BURNS...

  • Page 29: Carburetor - Adjust Idling

    CARBURETOR – Adjust idling (Keihin-FCR41) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.The idle speed is controlled by means of the adjusting wheel and the mixture control screw .

  • Page 30: Adjusting The Throttle Cable

    Adjusting the throttle cable * The throttle grip should always provide for a backlash of 3-5 mm 3-5 mm (0,12-0,20 in). Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. To adjust the throttle cables, dismount the seat and the tank together with spoilers.

  • Page 31: Engine Oil

    Engine oil API: SG, SH Only use synthetic high-quality oils (Shell Advance Ultra 4) meeting or sur- passing the quality requirements of API classes SG, or SH (for specifications TEMPERATUR see containers). – CAUTION 0°C 32°F NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE 10W 40 15W 40 10W 50...

  • Page 32: Changing And Bleeding The Microfilter

    Changing and bleeding the microfilter * Replace the microfilter while changing the engine oil. To do so, remove hexagon screws and take off the microfilter cover . Remove the micro- filter, clean its parts and check the O-ring on the microfilter lid for signs of damage.

  • Page 33: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 34 TROUBLE CAUSE REMEDY Engine does not rev high Loose carburetor jets Tighten jets Electronical ignition timing faulty Have ignition system checked Engine will not reach full Fuel supply partically interrupted or Clean and check fuel system as well as carburetor power carburetor dirty float is not tight...

  • Page 35: Cleaning

    CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 36: Technical Specifications - Engine

    TECHNICAL SPECIFICATIONS – ENGINE 625 SC, 625 SC SUPERMOTO 2002 Engine 625 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
  • Page 37 TIGHTENING TORQUES - ENGINE 625 SC, 625 SC SUPERMOTO 2002 M20x1,5 Loctite 243 + 170 Nm (125 ft.lb) Hexagon nut at primary gear Collar nut flywheel M12x1 left 60 Nm (44 ft.lb) Hexagon nut for inner clutch hub M18x1,5 Loctite 243 + 100 Nm (74ft.lb) Kickstarter stop screw M12x1,5...

  • Page 38: Technical Specifications - Chassis

    TECHNICAL SPECIFICATIONS - CHASSIS 625 SC, 625 SC SUPERMOTO 2002 625 SC 625 SC SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) 270 / 320 (10,8 / 12.8 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake...
  • Page 39 STANDARD ADJUSTMENT - FORK 625 SC 625 SC SUPERMOTO WP 0518W712 WP 0518W722 Compression adjuster Rebound adjuster 4,2 N/mm 5,0 N/mm Spring Spring preload 5 mm 9 mm Air chamber length 140 mm 130 mm Fork oil SAE 5 SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 625 SC 625 SC SUPERMOTO...
  • Page 40 321020...