KTM 400, 660, LC4 Engines - Repair, Service and Maintenance Manual

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KTM 400, 660, LC4 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for KTM 400, 660, LC4 Engines.
 

CONTENTS:

Service-Informations
- Adventure-Discoloring Fuel Tank
- 660 Sms Outer Clutch Hub
- Balancer Shaft
- Low Octane Fuel Adaption
General Information
- Models Without Frame Oil
- Changing The Engine Oil
- Changing The Oil Filter
- Changing The Microfilter
- Oil Circuit
- Oil Circuit 660 Smc
- Models With Frame Oil
- Changing The Engine Oil
- Changing The Fine Screen Filter
- Changing The Oil Filter
- Oil Circuit
- Secondary Air System
- Epc-System
- Special Tools
- Bleeding Of The Hydraulic Clutch
Removing And Refitting Engine
- Removing The Engine
- Refitting The Engine
Disassembling The Engine
- Drain Engine Oil
- Removing The Electric Starter Motor
- Removing The Clutch Release Lever And The Oil Hoses
- Removing The Oil Filter
- Removing The Epc Wiring Harness
- Removing The Ignition (Kokusan 4k-2)
- Removing The Ignition (Sem)
- Removing The Ignition (Kokusan 4k-3)
- Removing The Electric Starter Drive
- Removing The Cylinder Head Top Section
- Blocking The Crankshaft
- Removing The Camshaft And The Automatic Tensioner
- Removing Cylinder Head
- Removing Cylinder And Piston
- Removing Engine Sprocket
- Removing Clutch And Primary Drive
- Removing The Oil Pumps
- Removing The Timing Chain And The Timing Gear
- Removing The Clutch Release Shaft
- Parting Of Engine Housing
- Removing The Shift Mechanism
- Removing The Transmission Shafts
- Removing The Kickstarter Shaft
Servicing Individual Components
- Working On The Right Housing Half
- Working On The Left Housing Half
- Crankshaft
- Measuring And Adjusting Of Crankshaft Axial Play
- Checking The Piston
- Mounting Instructions For Piston Rings
- Piston Ring End Gap
- Measuring Piston And Cylinder, Determiningthe Piston Fitting Clearance
- Cylinder – Nikasil Coating
- Recoated Cylinder
- Disassembling The Cylinder Head And Checkingthe Components For Wear
- Disassembling The Cylinder Head Top Section Andchecking Components For Wear
- Pre-Assembling The Cylinder Head Top Section
- Checking The Components Of The Timing Mechanism For Wear
- Disassembling The Camshaft And Checking Thecomponents For Wear
- Pre-Assembling The Camshaft
- Automatic Tensioner
- Preassembly Of Automatic Tensioner
- Disassembling The Oil Pumps And Checking Thecomponents For Wear
- Oil Lines (Sx, Sxc)
- Oil Lines (Sc)
- Oil Lines (660 Smc)
- Oil Lines (Models With Frame Oil)
- Checking The Kickstarter Components For Wear
- Preassembly Of Kickstarter Shaft
- Clutch Cover
- Replacing Absorbing Elements Of The Outer Clutch Hub
- Checking The Clutch Components For Wear
- Checking The Shift Mechanism Components For Wear
- Preassembly Of Shift Shaft
- Shift Mechanism Support
- Balancer Shaft
- Disassembling And Reassembling The Water Pump
- Important Note Regards Working On Transmission
- Assembling The Main Shaft
- Assembling The Counter Shaft
- Removing The Intermediate Gear
- Checking The Freewheel
- Replacing The Freewheel Hub
- Electric Starter Motor
- Ignition (Kokusan 4k-2)
- Checking The Stator And The Pulse Generator (Kokusan 4k-2)
- Replacing The Stator (Kokusan 4k-2)
- Ignition (Sem)
- Checking The Stator (Sem)
- Replacing The Stator (Sem)
- Checking The Stator (Kokusan 4k-3)
- Replacing The Stator (Kokusan 4k-3)
Assembling The Engine
- Mounting The Kickstarter Unit
- Mounting Transmission And Shift Mechanism
- Adjustment Of Return Spring
- Pretensioning Of The Starter Spring
- Mounting Crankshaft
- Assembly Of Engine Housing
- Mounting Oil Filter
- Mounting The Engine Sprocket
- Mounting The Timing Gear And The Timing Chain
- Mounting The Oil Pumps
- Mounting The Balancer Shaft And The Primary Pinion
- Mounting The Clutch
- Mounting The Clutch Discs
- Installing The Clutch Release Shaft
- Adjusting The Clutch Release
- Measure Dimension „Y“
- Mounting Piston And Cylinder
- Mounting The Cylinder Head
- Mounting The Camshaft, Timing Marks
- Mounting The Water Pump
- Mounting The Cylinder Head Top Section
- Mounting The Automatic Tensioner
- Automatic Decompression Testing
- Adjustment Of Valve Clearance
- Mounting The Clutch Cover
- Mounting The Electric Starter Drive
- Mounting The Ignition (Kokusan 4k-2)
- Adjusting The Pulse Generator (Kokusan 4k-2)
- Mounting The Ignition (Sem)
- Adjustment Of Ignition Point (Sem)
- Mounting The Epc Wiring Harness
- Mounting The Ignition (Kokusan 4k-3)
- Adjustment Of Ignition Point (Kokusan 4k-3)
- Mounting The Oil Hoses
- Mounting The Clutch Release Lever
- Mounting The Electric Starter Motor
- Mounting The Water Hoses
- Pouring In Engine Oil
- Mounting The Kickstarter And The Shift Lever
Electrical
- Super Competition 1998
- Checking The Voltage Regulator-Rectifier
- Checking The Voltage Regulator
- Checking The Capacitor
- Lc4 Competition 1998
- Charging System
- Leakage Inspection
- Removing The Battery
- Charging The Battery
- Charging Voltage / Checking The Voltage Regulator
- Checking The Capacitor
- Checking The Neutral Switch
- Lc4 1998
- Charging System
- Leakage Inspection
- Removing The Battery
- Charging The Battery
- Charging Voltage / Checking The Voltage Regulator
- Checking The Capacitor
- Electric Starter System
- Checking The Start Auxiliary Relay
- Checking The Auxiliary Starting Relay For Faultless Operation
- Checking The Diode
- Checking The Starter Relay
- Checking The Electric Starter Motor
- Checking The Clutch Switch
- Checking The Emergency Off Switch
- Trouble Shooting In The Electric Starter Sytem
- Ignition System
- Cdi Unit
- Checking The Ignition Coil
- Trouble Shooting In The Ignition System
- Epc System
- Dismount / Renew Solenoid Valve For Epc
- Check Of Solenoid Valve For Epc
- Controller Of The Epc System
- Check Of Epc System Microswitch
- Replacing The Epc System Microswitch
- Check Of Idle Switch / Contact Screws
- Duke-E 1998
- Charging System
- Leakage Inspection
- Charging Voltage / Checking The Voltage Regulator
- Removing The Battery
- Charging The Battery
- Checking The Capacitor
- Electric Starter System
- Checking The Start Auxiliary Relay
- Checking The Auxiliary Starting Relay For Faultless Operation
- Checking The Diodes
- Checking The Clutch Switch
- Checking The Emergency Off Switch
- Checking The Starter Relay
- Checking The Electric Starter Motor
- Trouble Shooting In The Electric Starter Sytem
- Idle Switch
- Ignition System
- Cdi Unit
- Checking The Ignition Coil
- Spark Plug Connector
- Checking The Side Stand Relay
- Checking The Side Stand Switch
- Trouble Shooting In The Ignition System
- Sxc 1999
- Checking The Voltage Regulator
- Checking The Capacitor
- Sc 1999
- Checking The Voltage Regulator
- Checking The Capacitor
- Checking The Ignition Coil
- Duke 1999
- Charging System
- Leakage Inspection
- Charging Voltage / Checking The Voltage Regulator
- Removing The Battery
- Charging The Battery
- Checking The Capacitor
- Electric Starter System
- Checking The Start Auxiliary Relay
- Checking The Auxiliary Starting Relay For Faultless Operation
- Checking The Diodes
- Checking The Clutch Switch
- Checking The Emergency Off Switch
- Checking The Starter Relay
- Checking The Electric Starter Motor
- Trouble Shooting In The Electric Starter Sytem
- Checking The Idle Switch
- Ignition System
- Cdi Unit
- Checking The Ignition Coil
- Spark Plug Connector
- Checking The Side Stand Relay
- Checking The Side Stand Switch
- Trouble Shooting In The Ignition System
- Measurements With Peak Voltage Adapter
- Dynamic Generator Values 400/640 Lc4-E, 625 Sxc, Duke, Adventure
- Static Ignition Values 400/640 Lc4-E, 625 Sxc, Duke, Adventure
- Static Generator Values 400/640 Lc4-E, 625 Sxc, Duke, Adventure
- Static Ignition Values 400/620/625 Sc, 660 Smc
- Static Generator Values 400/620/625 Sc, 660 Smc
- Checking Speedometer And Speedometer Sensor
Fuel System
- Mikuni Bst 40
- Part-Load System
- Full-Load System
- Disassembling The Carburetor
- Assembling The Carburetor
- Checking/Adjusting The Throttle Sensor
- Adjust Idling Speed
- Adjusting The Throttle Cable
- Check Float Level
- Dell’orto
- Disassembling The Carburetor (Dell’orto Phm 40 Sd)
- Assembling The Carburetor (Dell’orto Phm 40 Sd)
- Disassembling The Carburetor (Dell’orto Phm 38 Nd)
- Assembling The Carburetor (Dell’orto Phm 38 Nd)
- Disassembling The Carburetor (Dell’orto Vhsb 38 Qs)
- Assembling The Carburetor (Dell’orto Vhsb 38 Qs)
- Check Float Level (Dell’orto 38 Nd / 40 Sd)
- Checking Axial Clearance Of Float (Dell’orto 38 Nd / 40 Sd)
- Adjust Hot Start Device (Dell’orto 40 Sd)
- Adjusting The Throttle Cable
- Adjusting The Choke Cable
- Keihin Fcr 41
- Disassembling The Carburetor
- Checking The Choke Slide
- Checking The Accelerator Pump
- Checking The Jet Needle
- Checking The Float Needle Valve
- Checking The Throttle Valve
- Assembling The Carburetor
- Adjusting The Position Of The Throttle Valve Sensor
- Checking The Throttle Valve Sensor
- Dismounting And Installing The Throttle Valve Sensor
- Adjust Idling Speed
- Checking/Adjusting The Float Height
- Keihin Fcr-Mx 41
- Disassembling The Carburetor
- Checking The Choke Slide
- Checking The Accelerator Pump
- Checking The Jet Needle
- Checking The Float Needle Valve
- Checking The Throttle Valve
- Assembling The Carburetor
- Adjusting The Position Of The Throttle Valve Sensor
- Checking The Throttle Valve Sensor
- Dismounting And Installing The Throttle Valve Sensor
- Adjust Idling Speed
- Checking/Adjusting The Float Height
Trouble Shooting
- Sx, Sxc, Sc, Smc)
- Lc4 Competition
- Lc4
Technical Specifications
- Model 1998
- Engine 400/540 Sxc
- Chassis 400/540 Sxc
- Engine 400/620 Sx, Sc
- Chassis 400/620 Sx, Sc
- Engine 620 Lc4 Competition
- Chassis 620 Lc4 Competition
- Engine 400/540 Sxc
- Chassis 400/640 Lc4
- Chassis 640 Adventure-R
- Chassis 640 Duke-E
- Model 1999
- Engine 400/540 Sxc, 620 Sx
- Chassis 400/540 Sxc, 620 Sx
- Engine 400/620 Sc
- Chassis 400/620 Sc
- Engine 620 Lc4 Competition
- Chassis 620 Lc4 Competition
- Engine 400/640 Lc4
- Chassis 400/640 Lc4
- Engine 640 Adventure-R
- Chassis 640 Adventure-R
- Engine 640 Duke
- Chassis 640 Duke
- Model 2000
- Engine Sc, Supermoto
- Chassis Sc, Supermoto
- Engine Lc4-E, Adventure, Duke
- Chassis Lc4-E Supermoto
- Chassis 640 Adventure-R
- Chassis 640 Duke
- Chassis 640 Duke Aus
- Engine 400 Sxc
- Chassis 400/540 Sxc
- Model 2001
- Engine 620 Sc, Supermoto
- Chassis 620 Sc, Supermoto
- Engine Lc4-E, Adventure, Duke
- Chassis Lc4-E, Supermoto
- Chassis 640 Lc4 Adventure
- Chassis 640 Duke
- Chassis 640 Duke Usa, Aus
- Modell 2002
- Engine 625 Sc, Supermoto
- Chassis 625 Sc, Supermoto
- Engine 640 Lc4, Adventure, Duke
- Chassis 640 Lc4, Supermoto
- Chassis 640 Adventure
- Chassis 640 Duke
- Modell 2003
- Engine 625 Sxc
- Chassis 625 Sxc
- Engine 640 Lc4, Adventure, Duke
- Chassis 640 Lc4, Supermoto
- Chassis 640 Lc4 Adventure
- Chassis 640 Duke
- Engine 660 Smc
- Chassis 660 Smc
- Tightening Torques
- Engine
- Chassis
- Assembly Clearance, Wear Limit
Periodic Maintenance Schedule
- Model 1998
- Sx, Sxc, Sc
- Lc4 Competition, Lc4
- Adventure-R
- Duke
- Model1999
- Sx, Sxc, Sc
- Lc4 Competition, Lc4
- Adventure-R
- Duke
- Model 2001
- 620 Sc
- Lc4-E, Adventure
- Duke
- Model 2002
- 625 Sc
- Lc4, Adventure
- Duke
- Model 2003
- 625 Sxc, 660 Smc
- 640 Lc4, 640 Lc4 Adventure
- Duke
Wiring Diagrams
- Model1998
- 400 / 540 Sxc
- 400 / 620 Sc (For Competition)
- 400 / 620 Sc (For Australia)
- 400 / 620 Sc (For Germany)
- 640 Lc4 (For Usa)
- 640 Adventure-R (Dell Orto)
- 640 Duke-E
- 620 Lc4 Competition
- 400 Lc4
- 640 Lc4
- Model1999
- 400 / 540 Sxc
- 400 / 540 Sxc (Australia)
- 400 / 620 Sc
- 400 / 620 Sc (Australia)
- 640 Adventure-R (Dell Orto)
- 640 Adventure-R (Mikuni)
- 640 Duke
- 620 Lc4 Competition
- 400 Lc4
- 640 Lc4, Supermoto
- 640 Lc4 (Usa)
- Model2000
- 400 / 620 Sc / 620 Sc Supermoto
- 640 Adventure-R
- 640 Duke
- 400 Lc4-E
- 640 Lc4-E, Supermoto
- 400 / 640 Lc4-E (Usa)
- Model2001
- 620 Sc / 620 Sc Supermoto
- 640 Lc4 Adventure
- 640 Duke
- 400 Lc4-E, 400 / 640 Lc4-E Usa
- 640 Lc4-E, Supermoto
- Model2002
- 625 Sc / 625 Sc Supermoto
- 640 Lc4 Adventure
- 640 Duke
- 640 Lc4, 640 Lc4 Supermoto
- 640 Lc4, 640 Lc4 Supermoto Usa
- Model2003
- 625 Sxc
- 640 Lc4, 640 Lc4 Supermoto
- 640 Lc4 Adventure
- 640 Duke
- 660 Smc