Trouble Shooting - KTM 625 LC4 SUPERCOMPETITION Owner's Handbook Manual

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
TROUBLE
Engine will not start
32
Engine will not idle
Engine does not rev high

TROUBLE SHOOTING

CAUSE
Operating error
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has accu-
mulated in the float chamber
Fuel supply interrupted
Flooded engine
Sooty or wet spark plug
Electrode gap too large
Spark plug connector or spark plug
faulty
If connector oxidates from genera-
tor to ignition coil
Short circuit cable scored in wiring
harness, ignition lock, emergency
OFF switch or short circuit button
faulty
Water in short emergency OFF
switch
The plug connection of the CDI-
unit, the pulse generator or the
ignition coil has oxydized
Water in carburetor or jets blocked
Carburetor does not fit in properly
at intake flange
Idling jet blocked
Adjusting screws on carburetor
uncorrect adjusted
Ignition system faulty
Carburetor fuel level too high
because float needle valve is dirty
or worn out
REMEDY
Switch on ignition, switch on emergency OFF switch, open fuel
tap, tank fuel, do not use choke. Pay attention to starting off
information (see driving instructions).
The easily inflammable components of the new fuels evapo-
rate during longer periods of standstill.
When the motorcycle has been out of operation for more than
a week, it is therefore recommended to drain the old fuel from
the float chamber. The engine will immediately start off when
the float chamber is filled with new fuel.
Close fuel tap, loosen fuel hose at carburettor, lead into a
basin and open fuel tap,
– if fuel leaks out, clean carburetor
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
In order to "pump the engine free", pull the hand decompres-
sion lever, fully rev up the engine, actuate the kickstarter 5 to
10 times. Then, start the engine as described above.
If the engine fails to start, unscrew the spark plug and dry it.
Clean or replace spark plug
Adjust spark plug electrode gap to 0,9 mm
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate kickstarter, a strong spark
must be produced at the spark plug
– If no spark is produced, loosen spark plug cap from ignition
cable, hold about 5 mm from ground and actuate kickstarter
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Remove fuel tank, clean connector and treat with contact
spray
Remove fuel tank, draw off black/yellow cable from cable of
ignition coil and check spark.
– If a spark is produced, seek fault in short circuit current
Remove 2-pole connector located underneath the headlight
mask, treat emergency OFF switch with contact spray
Remove the seat and the fuel tank. Clean the plug connection
and treat it with contact spray
Dismount and clean carburetor
Check if carburetor is fitted in correctly
Dismount carburetor and clean jets
Adjust carburettor
Have ignition system checked
Dismount carburetor and check if worn out