1998-2003 KTM 625 SXC 660 SMC Service & Repair Manual

OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.211.44 625 SMC, SXC BEDIENUNGSANLEITUNG2005

ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. © 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only. Please 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: – IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB! – IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR- CYCLE’S TRAFFIC SAFETY! COMSUMER INFORMATION FOR AUSTRALIA ONLY 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 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.

ENGLISH 2 INTRODUCTION » We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it. We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer. For your own safety, use KTM-approved parts and accessories only. 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. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer. Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmen- tally conscious and respect the rights of others. We wish you a lot of fun when driving ! KTM-SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA Attachments: 1 spare parts manual chassis & engine

ENGLISH 3 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations. The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty. The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule. The warranty or guarantee shall become void for damage and consequential damage caused by manipu- lations or conversions to the motorcycle. The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached. This motorcycle is only authorized for public roads in the original homologated (throttled) version. Without this performance restriction (i.e. dethrottled), this motorcycle is only authorized to be driven off-road but not on public roads. The 625 SXC model is designed for off-road endurance competitions (Enduro) and not predominantly for motocross racing. The SMC models are only allowed on public roads in the original homologated (throttled) version. Without this performance restriction (i.e. dethrottled), these models are only allowed to be driven in Supermoto competitions but not on public roads. No warranty will be assumed if the bike is used in races or competitions. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

ENGLISH 4 Page Adjusting of free travel at the hand brake lever (SXC) .29 Changing the basic position of the handbrake lever (SMC) .29 General information about KTM disc brakes . . . . . . . .29 Checking of brake fluid level - front brake . . . . . . . . .30 Refilling the front brake fluid reservoir . . . . . . . . . . .30 Checking the front brake pads (SXC) . . . . . . . . . . . . .31 Checking the front brake pads (SMC) . . . . . . . . . . . .31 Replacing front brake pads (SXC) . . . . . . . . . . . . . . .31 Replacing the front brake pads (SMC) . . . . . . . . . . . .32 Check the rear brake fluid level . . . . . . . . . . . . . . . .32 Refilling the rear brake fluid reservoir . . . . . . . . . . . .32 Changing the basic position of the brake pedal . . . . . .33 Checking the rear brake pads . . . . . . . . . . . . . . . . . .33 Replacing the rear brake pads . . . . . . . . . . . . . . . . .33 Dismounting and mounting the front wheel (SXC) . . . .34 Dismounting and mounting the front wheel (SMC) . . .34 Dismounting and mounting the rear wheel . . . . . . . . .35 Checking the shock absorption rubbers in the rear hub (SMC) .35 Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .36 Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .36 Check/set distance of the magnetic sensor . . . . . . . . .36 Battery for digital speedometer . . . . . . . . . . . . . . . . .36 Battery (SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .37 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Replacing headlight lamp/parking light lamp . . . . . . .38 Exchanging the brake light and tail light bulb (SXC) . .39 Exchanging the brake light and tail light bulb (SMC) .39 Checking the coolant level . . . . . . . . . . . . . . . . . . . .40 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Cleaning the air filter (SXC) . . . . . . . . . . . . . . . . . . .41 Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . .41 Exhaust system (SXC) . . . . . . . . . . . . . . . . . . . . . . .42 Exhaust system (SMC) . . . . . . . . . . . . . . . . . . . . . . .42 Adjusting the throttle cable . . . . . . . . . . . . . . . . . . .43 Checking the adjustment of the hand decompression cable .43 Changing the original position of the clutch lever . . . .44 Checking the oil level of the hydraulic clutch . . . . . .44 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .44 Activating the ignition curve for low-octane fuel . . . . .45 Draining the float chamber of the carburetor . . . . . . .45 CARBURETOR – Adjust idling . . . . . . . . . . . . . . . . .45 Adjusting the mixture control screw . . . . . . . . . . . . .46 Checking the float level (float height) . . . . . . . . . . . .46 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Checking the engine oil level . . . . . . . . . . . . . . . . . .46 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Oil and screen filter change, bleeding of the oil system .47 Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .48 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .49 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 CONSERVATION FOR WINTER OPERATION . . . . . . . . . .51 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Reinitiation after time of storage . . . . . . . . . . . . . . . .51 TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . .52 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . .54 HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .56 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix Page IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . . . . . . . . .3 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number, engine type . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6 Hand brake lever (SXC) . . . . . . . . . . . . . . . . . . . . . . .6 Hand brake lever (SMC) . . . . . . . . . . . . . . . . . . . . . . .6 Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .7 Overview of the electronic speedometer functions . . .11 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Combination switch . . . . . . . . . . . . . . . . . . . . . . . . .12 Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Emergency OFF button . . . . . . . . . . . . . . . . . . . . . .12 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Hot start device . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Handlebar lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Compression damping of fork . . . . . . . . . . . . . . . . . .15 Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .15 Compression damping of shock absorber . . . . . . . . . .15 Rebound damping of shock absorber . . . . . . . . . . . . .15 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Instructions for initial operation . . . . . . . . . . . . . . . .16 Running in the LC4 models . . . . . . . . . . . . . . . . . . .16 Accessories and payload . . . . . . . . . . . . . . . . . . . . .16 DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .17 Check the following before each start . . . . . . . . . . . .17 Starting when the engine is cold . . . . . . . . . . . . . . . .18 Starting when the engine is warm or hot . . . . . . . . . .18 What to do when the engine is “flooded” . . . . . . . . . .18 Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . .18 Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .19 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .21 MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .23 Removal of seat (SXC) . . . . . . . . . . . . . . . . . . . . . . .23 Tool set (SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Removal of seat (SMC) . . . . . . . . . . . . . . . . . . . . . .24 Tool set (SMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Check and adjust steering head bearing . . . . . . . . . . .24 Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .25 Cleaning the dust sleeves of the telescopic fork . . . . .25 How to change the handlebar position . . . . . . . . . . . .25 Changing the spring preloading of the shock absorber .26 Checking rubber ring on the WP rear shock absorber . .26 Lubricate rear suspension linkage . . . . . . . . . . . . . . .26 Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .27 Checking chain tension . . . . . . . . . . . . . . . . . . . . . .27 Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .28 INDEX »

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1998-2003 KTM 625 SXC 660 SMC Service & Repair Manual

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