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KTM 620 2001 Owner's Handbook Manual

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Summary of Contents for KTM 620 2001

  • Page 3 (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 4 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 5: Table Of Contents

    Changing the spring preloading of the shock absorber ...19 Lubricate rear suspension linkage ........19 TECHNICAL SPECIFICATIONS - CHASSIS......38 Checking chain tension...........19 WIRING DIAGRAMME ..........APPENDIX Correct chain tension............20 Chain maintenance............20 Chain wear..............20 General informations about KTM disc brakes....21 Adjusting of free travel at the hand brake lever ....21...

  • Page 6: 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 7: 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. Speedometer – digital Some models are equipped with a digital speedometer KMH = Speed, max.

  • Page 8: 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 9: Choke

    Choke The choke operating element is located on the engine. Pull the knob turn it (approx. 90°) to open a bore in the carburetor through which the engine can take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts.

  • Page 10: Handlebar Lock

    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 EVER LEAVE THE KEY INSERTED IN THE LOCK F YOU TURN THE STEERING TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork...

  • Page 11: Driving Instructions

    The maximum permissible laden weight is brake pads. Arrange for the braking system to be checked made up of the following components: by a KTM specialist, as complete failure of the braking – Motorcycle ready for operation and tank full system can be avoided.
  • 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

    Stopping and parking When shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to Apply the brakes fully and put the engine into neutral. To stop the next gear. Let clutch lever go slowely and open throttle or the engine, switch off the ignition or pull the short circuit but- shift down again.

  • Page 14: Periodic Maintenance-Schedule

    PERIODIC MAINTENANCE SCHEDULE 2001 620 SC 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 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...
  • 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 Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals...

  • 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

    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 includes 2 bores arranged at a distance of 15 mm (0,6 in) from one another.
  • Page 19 1. use the right button to select 2. push the left button until the cor- TOTAL MILEAGE „DST“ the position to be changed rect figure is shown on the display after changing battery 1 sec 5. push the button on the back with a sharp object approx.

  • Page 20: Check/Set Distance Of The Magnetic Sensor

    WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication "TRP" is 2. use the right button to select the 5 sec activated and push the button on the position to be changed back approx. seconds ("WS" appears) 1 sec 5. push the button on the back 3.

  • Page 21: Changing The Spring Preloading Of The Shock Absorber

    THE LUBRICATING NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS 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 22: Correct Chain Tension

    Correct chain tension – Loosen collar nut , loosen lock nuts , and turn right and left adjusting screws equally far. Tighten lock nuts – Before tightening the collar nut, verify that the chain adjusters sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel.

  • Page 23: General Informations About Ktm Disc Brakes

    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.

  • Page 24: Check The Front Brake Pads

    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 25: 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 26: 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 27: Dismounting And Mounting The Rear Wheel

    Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer tou- ches the ground. Loosen the collar nut , hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper sup- port is still held.

  • Page 28: Tires, Air Pressure

    (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 29: 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 30: 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 31: Carburetor - Adjust Idling

    CARBURETOR – Adjust idling * 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. Idling is controlled by the throttle stop screw and the mixture control screw...

  • Page 32: Adjusting The Throttle Cable

    Adjusting the throttle cable There must always be a 3-5 mm (0,12-0,20 in) play in the throttle cable. To 3-5 mm check this, move back the protective cover on the twist grip. You must be able to lift the outer covering of the cable 3-5 mm from the adjustment screw , until resistance is felt.

  • Page 33: 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 34: 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 35: 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 36 TROUBLE CAUSE REMEDY Engine will not reach full Valve gap to small Adjust valve gap power Loss of compression because hand Check setting of the hand decompression cable decompressor has no play Electronical ignition timing faulty Have ignition system checked Engine stops or splutters in Insuffient fuel Clean and check fuel system and carburetor...

  • Page 37: 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 38: Technical Specifications - Engine

    TECHNICAL SPECIFICATIONS – ENGINE 620 SC, 620 SC SUPERMOTO 2001 Engine Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 609 ccm Bore / Stroke 101 / 76 mm Ratio 10,4 : 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 39 ASSEMBLY CLEARANCE, WEAR LIMIT - ENGINE 620 SC Crank shaft axial play ..........0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud........max. 0,04 mm (0,002 in) Connecting rod bearing radial play ..........max. 0,05 mm (0,002 in) axial play............max. 1,00 mm (0,04 in) Piston forged assembly clearance ........max.

  • Page 40: Technical Specifications - Chassis

    TECHNICAL SPECIFICATIONS - CHASSIS 620 SC, 620 SC SUPERMOTO 2001 620 SC 620 SC SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 295 / 320 mm (11,6 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated...
  • Page 41 320591...