KTM 400, 450, 520, 530, 540, 620, 625, 640,660 EXC/LC4/SC/SMC/SX/XC/Adventure/Duke/Supermoto Repair Service Manual 1998-2009
Complete service repair manual with Electrical Wiring Diagrams for KTM 400, 450, 520, 530, 540, 620, 625, 640,660 EXC, LC4, SC, SMC, SX, XC, Adventure, Duke, Supermoto, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KTM 400, 450, 520, 530, 540, 620, 625, 640,660 EXC/LC4/SC/SMC/SX/XC/Adventure/Duke/Supermoto workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
3206054en - KTM 2008 REPAIR MANUAL 450 EXC-R EU, 450 EXC-R AUS_UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS_UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA.pdf
3206064en - KTM 2009 Repair Manual 400 EXC EU, 400 EXC AUS, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC SIX DAYS EU, 450 XC-W USA, 450 XC-W ZA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 450 EXC USA, 530 EXC USA.pdf
KTM 400-520 SX_EXC Racing Service Manual (DE).pdf
KTM 400-660 LC4 Service Manual.pdf
KTM 400-660LC42003 Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,121 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MODEL: KTM
YEAR: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
MODEL: 400 EXC EU, 400 EXC AUS, 400 EXC Racing, 400 EXC Racing USA, 400 LC4, 400 LC4-E, 400 SC, 400 SXC, 400 SX Racing, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC USA, 450 EXC SIX DAYS EU, 450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 450 XC-W USA, 450 XC-W ZA, 520 SX Racing, 520 EXC Racing, 520 EXC Racing USA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 530 EXC USA, 530 EXC-R EU, 530 EXC-R AUS/UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA, 540 SXC, 620 LC4, 620 SC, 620 SC SUPERMOTO, 625 SC, 625 SC SUPERMOTO, 625 SXC, 640 ADVENTURE-R, 640 DUKE, 640 DUKE-E, 640 LC4, 640 LC4 ADVENTURE, 640 LC4-E, 640 SUPERMOTO, 660 RALLY, 660 SMC
--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
"'09 400-450-530.pdf"
248 pages; 2009 REPAIR MANUAL for 400 EXC EU, 400 EXC AUS, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC SIX DAYS EU, 450 XC-W USA, 450 XC-W ZA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 450 EXC USA, 530 EXC USA
"'08 450-530 EXC-R_XCR-W.pdf"
191 pages; 2009 REPAIR MANUAL for 450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA
"'98-'05 400-660 LC4"
62.9MB, 1,000+ pages; 400-660LC4 1998-2005 REPAIR MANUAL;
MODEL 1998
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
MODEL 1999
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)
MODEL 2000
400 / 620 SC / 620 SC SUPERMOTO
640 ADVENTURE-R
640 DUKE
400 LC4-E
640 LC4-E, SUPERMOTO
400 / 640 LC4-E (USA)
MODEL 2001
620 SC / 620 SC SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
400 LC4-E, 400 / 640 LC4-E USA
640 LC4-E, 640 LC4-E SUPERMOTO
MODEL 2002
625 SC / 625 SC SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
640 LC4, 640 LC4 SUPERMOTO
640 LC4, 640 LC4 SUPERMOTO USA
MODEL 2003
660 SMC
625 SXC
640 LC4, 640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
MODEL 2004
625 SXC
640 LC4, 640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
660 SMC
MODEL 2005
625 SXC
625 SMC
640 LC4
640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
660 SMC
660 RALLY
"'03 400-660 LC4.pdf"
387 pages; 400-660LC4 1998-2003 REPAIR MANUAL;
400 LC4, 400 LC4-E, 400 SC, 400 SXC, 540 SXC, 620 LC4, 620 SC, 620 SC SUPERMOTO, 625 SC, 625 SC SUPERMOTO, 625 SXC, 640 ADVENTURE-R, 640 DUKE, 640 DUKE-E, 640 LC4, 640 LC4 ADVENTURE, 640 LC4-E, 640 SUPERMOTO, 660 SMC
"'00 400-520 SX_EXC Racing (DE).pdf"
103 pages, German Language; 400-520 SX/EXC Racing Reparaturanleitung
400 SX Racing, 400 EXC Racing, 400 EXC Racing USA, 520 SX Racing, 520 EXC Racing, 520 EXC Racing USA
TABLE OF CONTENTS
HOME...0
MEANS OF REPRESENTATION...8
IMPORTANT NOTES...9
LOCATION OF SERIAL NUMBERS...10
Chassis number...10
Type label...10
Key number (all EXC models)...10
Engine number...11
Fork part number...11
Shock absorber part number...11
MOTORCYCLE...12
Jacking up the motorcycle...12
Removing the motorcycle from the work stand...12
Starting...12
Starting the motorcycle for checking...13
01/FORK, TRIPLE CLAMP...14
Adjusting compression damping of fork...14
Adjusting rebound damping of fork...14
Adjusting spring preload of the fork...14
Bleeding fork legs...15
Cleaning the dust boots of the fork legs...15
Loosening the fork protection...15
Positioning the fork protection...16
Removing the fork legs...16
Installing fork legs...16
Removing the fork protector...17
Installing the fork protector...17
Performing a fork service...18
Disassembling the fork legs...18
cartridge, disassembling...21
Disassembling the compression damping fitting...23
Checking the fork legs...23
Assembling the compression damping fitting...24
Assembling the cartridge...25
Assembling the fork legs...27
Greasing the steering head bearing...31
Removing the lower triple clamp (EXC SIX DAYS, XC‑W USA, EXC USA)...31
Installing the lower triple clamp (EXC SIX DAYS, XC‑W USA, EXC USA)...32
Removing the lower triple clamp (EXC EU, EXC AUS, XC‑W ZA)...32
Installing the lower triple clamp (EXC EU, EXC AUS, XC‑W ZA)...33
Checking the play of the steering head bearing...34
Adjusting play of steering head bearing (EXC SIX DAYS, XC‑W USA, EXC USA)...34
Adjusting play of steering head bearing (EXC EU, EXC AUS, XC‑W ZA)...35
02/HANDLEBAR, INSTRUMENTS...36
Handlebar position...36
Adjusting handlebar position...36
Adjusting basic position of clutch lever...38
Checking the choke cable routing (EXC EU, EXC SIX DAYS)...38
Checking the choke cable play (EXC EU, EXC SIX DAYS)...38
Adjusting the choke cable play (EXC EU, EXC SIX DAYS)...38
Checking of the routing of the throttle cable...39
Checking the play in the throttle cable...39
Adjusting the play in the throttle cable...39
03/FRAME...40
Removing the engine sprocket cover...40
Installing the engine sprocket cover...40
04/SHOCK ABSORBER, SWINGARM...41
Adjusting high-speed compression damping of the shock absorber...41
Adjusting the low-speed compression damping of the shock absorber...41
Adjusting rebound damping of shock absorber...42
Measuring rear wheel sag unloaded...42
Checking static sag of shock absorber...42
Checking riding sag of shock absorber...43
Adjusting spring preload of the shock absorber...43
Adjusting riding sag...44
Removing the shock absorber...44
Installing the shock absorber...44
Performing a shock absorber service...45
Removing the spring...45
Disassembling the shock absorber...46
Disassembling the piston rod...47
Disassembling the seal ring retainer...48
Replacing the pilot bushing...49
Checking the shock absorber...49
Disassembling the rebound adjuster...50
Removing the heim joint...51
Installing the heim joint...51
Assembling the rebound adjuster...52
Assembling the seal ring retainer...53
piston rod, assembling...53
Assembling the damper...55
Bleeding and filling the damper...57
Filling the damper with nitrogen...59
Installing the spring...60
05/EXHAUST...62
Removing main silencer...62
Installing the main silencer...62
Removing the manifold...62
Installing the manifold...62
06/AIR FILTER...63
Dismounting the air filter box lid...63
Installing the air filter box lid...63
Removing the air filter...63
Installing the air filter...63
Cleaning air filter...64
Removing the carburetor connection boot...64
Installing the carburetor connection boot...64
07/FUEL TANK, SEAT, TRIM...65
Opening filler cap...65
Closing filler cap...65
Removing the seat...65
Mounting the seat...65
Dismounting the fuel tank...65
Installing the fuel tank...66
Fuel tap...67
08/MASK, FENDER...68
Removing the front fender...68
Installing the front fender...68
Removing headlight mask with headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...68
Refitting the headlight mask with the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...68
Removing the start number plate (XC‑W USA)...69
Installing the start number plate (XC‑W USA)...69
09/FRONT WHEEL...70
Removing the front wheel...70
Installing the front wheel...70
Checking the brake discs...71
Removing the front brake disc...71
Installing the front brake disc...72
Checking the tire condition...72
Checking tire air pressure...72
Checking spoke tension...73
10/REAR WHEEL...74
Removing the rear wheel...74
Installing the rear wheel...74
Removing the rear brake disc...75
Installing the rear brake disc...75
Checking chain tension when fitting rear wheel...75
Adjusting chain tension - fitting rear wheel...76
Checking the chain tension...76
Adjusting chain tension - after checking...77
Adjusting the chain tension...77
Adjusting chain guide...78
Checking the rear sprocket / engine sprocket for wear...78
Checking chain wear...79
Checking for chain dirt accumulation...79
Cleaning the chain...79
11/WIRING HARNESS, BATTERY...80
Removing a fuse...80
Installing the fuse...80
Removing the battery...80
Installing the battery...81
Recharging the battery...81
Checking the closed current...82
Checking the charging voltage...82
Checking the voltage regulator...83
Checking the charging current...84
Checking the starter relay...84
13/BRAKE SYSTEM...86
Checking the front brake linings...86
Removing front brake linings...86
Mounting front brake linings...86
Changing the front brake linings...87
Checking free travel of hand brake lever...88
Adjusting basic position of handbrake lever (all XC‑W models)...88
Adjusting free travel of handbrake lever (all EXC models)...88
Checking the brake fluid level of the front brake...89
Adding front brake fluid...89
Changing the front brake fluid...90
Checking rear brake linings...91
Removing rear brake linings...91
Mounting rear brake linings...91
Changing the rear brake linings...92
Checking free travel of foot brake lever...93
Adjusting basic position of foot brake lever...93
Checking the brake fluid level of the rear brake...93
Adding rear brake fluid...94
Changing the rear brake fluid...94
14/LIGHTING SYSTEM, INSTRUMENTS...96
Adjusting the speedometer functions...96
kilometers or miles, setting...96
Activating the additional functions...97
Setting the wheel circumference...97
Setting the clock...98
Checking the headlamp setting (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...98
Adjusting the beam width of the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...98
30/ENGINE...100
Removing the engine...100
Installing the engine...101
30/DISASSEMBLING THE ENGINE...103
Preparations...103
Draining the engine oil...103
Removing the oil filter...103
Draining the gear oil, removing the gear oil screen...103
Removing the starter engine...104
Removing the spark plug...104
Removing the valve cover...104
Removing the shift lever...104
Removing the generator cover...105
Setting the engine to ignition top dead center...105
Removing the timing chain tensioner...106
Removing the camshaft...106
Removing the cylinder head...106
Removing the piston...106
Removing the rotor...107
Removing the balance weight...107
Removing the timing chain guide rail...107
Removing the timing chain tensioning rail...108
Removing the timing chain securing guide...108
Removing the timing chain...108
Removing the ignition pulse generator...108
Removing the suction pump...108
Removing the kickstarter...109
Removing the water pump cover...109
Removing the clutch cover...109
Disassembling the clutch disks...110
Removing the primary gear nut...110
Removing the outer clutch hub...110
Removing the balancer shaft...111
Removing the torque limiter...111
Removing the starter idler gear...111
Removing the kickstarter shaft...111
Removing the kickstarter idler gear...112
Removing the shift shaft...112
Removing the shift drum locating...112
Removing the locking lever...112
Removing the oil pump gears...112
Removing the oil pumps...113
Removing the primary gear...113
Removing the free wheel gear...113
Removing the left section of the engine case...114
Removing the shift rails...115
Removing the shift drum...115
Removing the shift forks...115
Removing the transmission shafts...115
Removing the crankshaft...116
30/ENGINE - WORK ON THE INDIVIDUAL PARTS...117
Working on the right section of the engine case...117
Working on the left section of the engine case...118
Removing the oil pressure regulator valve...120
Checking spring length of oil pressure regulator valve...120
Installing the oil pressure regulator valve...120
Removing the crankshaft seal ring in the clutch cover...120
Fitting the crankshaft seal ring into the clutch cover...120
Removing the water pump...121
Installing the water pump...121
Checking the balancer shaft...122
Removing the timing chain sprocket...122
Installing the timing chain sprocket...123
Changing the connecting rod, conrod bearing and crank pin...123
Checking crankshaft run-out at bearing pin...125
cylinder - Nikasil® coating...125
Checking/measuring cylinder...125
Checking/measuring the piston...126
Checking the piston ring...126
Piston/cylinder - determining the mounting clearance...127
Checking the oil pumps for wear...127
Disassembling the autodecompressor...127
Assembling the autodecompressor...128
Checking camshaft...128
Checking the timing assembly...129
Preparing the timing chain tensioner for installation...129
Removing the rocker arm...130
Removing the valves...130
Changing camshaft bearing...131
Checking valves...131
Checking valve springs...132
Checking valve spring seat...132
Checking the cylinder head...132
Checking the rocker arm shafts...133
Installing valves...133
Installing the rocker arm...134
Checking clutch...134
Checking shift mechanism...135
Preassembling the shift shaft...136
Dismantling the main shaft...136
Assembling the main shaft...137
Dismantling the countershaft...137
Assembling the countershaft...138
Checking the transmission...138
Premounting the kickstarter shaft...139
Checking the electric starter mode...140
Removing the freewheel...141
Checking the freewheel...141
Installing the free-wheel...141
30/ENGINE ASSEMBLY...143
Installing the crankshaft...143
Installing the transmission shaft...143
Installing the shift forks...143
Installing the shift drum...144
Installing the shift rails...144
Installing the left engine case...144
Installing the free wheel gear...145
Installing the primary gear...145
Installing the oil pumps...145
Installing the oil pump gears...146
Installing the locking lever...146
Installing the shift drum locating...146
Installing the shift shaft...146
Installing the kickstarter idler gear...147
Installing the kickstarter shaft...147
Installing the starter idler gear...147
Installing the torque limiter...147
Installing the balancer shaft...148
Installing the outer clutch hub...148
Installing the primary gear nut...149
Installing the clutch discs...149
Installing the clutch cover...149
Installing the water pump cover...150
Installing the kickstarter...150
Installing the suction pump...150
Installing the ignition pulse generator...151
Installing the timing chain...151
Installing the timing chain securing guide...151
Installing the timing chain tensioning rail...151
Installing the timing chain guide rail...152
Installing the balance weight...152
Installing the rotor...152
Installing the piston...152
Installing the cylinder head...154
Installing the camshaft...155
Installing the timing chain tensioner...155
Checking the valve clearance...156
Adjusting the valve clearance...156
Installing the generator cover...156
Installing the shift lever...157
Installing the valve cover...157
Installing the spark plug...157
Installing the starter motor...157
Mounting oil filter...158
Filling up with engine oil...158
Filling up with gear oil...158
Removing the engine from the work stand...159
31/CARBURETOR...160
Choke (EXC AUS, XC‑W, EXC USA)...160
Choke (EXC EU, EXC SIX DAYS)...160
Removing the carburetor...160
Disassembling the carburetor...161
Checking/adjusting the carburetor components...163
Checking/adjusting the accelerator pump...164
Checking the choke slide...164
Checking the jet needle...164
Checking the throttle slide...165
Checking the needle jet...165
Checking the float needle valve...165
Checking/adjusting the float level...166
Checking/setting the throttle slide opening...166
Checking the throttle valve sensor...166
Adjusting the position of the throttle position sensor...167
Assembling the carburetor...168
Installing the carburetor...170
Carburetor - adjusting idle...171
Emptying the carburetor float chamber...172
32/CLUTCH...174
Checking fluid level of hydraulic clutch...174
Changing the hydraulic clutch fluid...174
33/TRANSMISSION...176
Removing the engine sprocket...176
Installing the engine sprocket...176
35/WATER PUMP, COOLING SYSTEM...177
Cooling system...177
Checking the antifreeze and coolant level...177
Checking the coolant level...178
Draining coolant...178
Refilling coolant...179
38/LUBRICATION SYSTEM...180
Oil circuit...180
Checking engine oil level...180
Changing engine oil and oil filter, cleaning engine oil screen...181
Draining engine oil, cleaning engine oil screen...181
Removing the oil filter...181
Mounting oil filter...182
Filling up with engine oil...182
Topping up engine oil...183
Checking the engine oil pressure...183
Checking the gear oil level...184
Changing gear oil, cleaning gear oil screen...184
Draining gear oil, cleaning gear oil screen...184
Filling up with gear oil...185
Adding gear oil...185
39/IGNITION SYSTEM...187
Checking the ignition system...187
Checking the ignition coil...188
Checking the spark plug connector...189
Checking the CDI controller...189
Checking the ignition pulse generator...189
Checking the generator...190
Removing the stator...192
Mounting the stator...192
40/ELECTROSTARTER...193
Checking the starter motor...193
TROUBLESHOOTING...194
TECHNICAL DATA - ENGINE...196
Capacity - engine oil...196
Capacity - gear oil...197
Capacity - coolant...197
TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS...198
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...199
TECHNICAL DATA - CARBURETOR...201
400 EXC...201
400 XC-W USA...201
450 EXC EU/AUS, 450 EXC SIX DAYS...201
450 EXC USA...202
450 XC-W...202
530 EXC EU/AUS, 530 EXC SIX DAYS...202
530 EXC USA...203
530 XC‑W...203
TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES...204
TECHNICAL DATA - CHASSIS...205
Lighting equipment...206
Tires...206
Capacity - fuel...206
TECHNICAL DATA - FORK...207
TECHNICAL DATA - SHOCK ABSORBER...208
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS...209
CLEANING...210
Cleaning motorcycle...210
STORAGE...211
Storage...211
Putting into operation after storage...211
SERVICE SCHEDULE...212
Important maintenance work to be carried out by an authorized KTM workshop...212
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)...213
Important checks and maintenance work to be carried out by the rider...214
WIRING DIAGRAM...216
Wiring diagram (EXC EU, EXC AUS, EXC‑R SIX DAYS)...216
Wiring diagram (EXC USA)...220
Wiring diagram (all XC‑W models)...224
OPERATING SUBSTANCES...226
AUXILIARY SUBSTANCES...228
SPECIAL TOOLS...230
STANDARDS...242
INDEX...243
Bed_auswahl_LC4_E...2
Drucksortenwahl_LC4_E...3
Federbein_4681_E...4
Gabel_auswahl_LC4_E...65
RA_LC4_komplett_E_05...66
HOME...0
NOTES AND PREFACE...0
Title page and file spine...66
Important information...72
Updating instruction...72
Explanation update...74
Introduction...76
Reply fax for repair manuals...78
TABLE OF CONTENTS...70
GENERAL INFORMATION...80
MODELS WITHOUT FRAME OIL...82
CHANGING THE ENGINE OIL...82
CHANGING THE OIL FILTER...82
CHANGING THE MICROFILTER...83
OIL CIRCUIT...84
OIL CIRCUIT 660 SMC (MODEL 2003)...85
MODELS WITH FRAME OIL...86
CHANGING THE ENGINE OIL...86
CHANGING THE FINE SCREEN FILTER...86
CHANGING THE OIL FILTER...87
OIL CIRCUIT...88
OIL CIRCUIT 660 SMC (FROM MODEL 2004 ON)...89
SECONDARY AIR SYSTEM...90
EPC-SYSTEM...92
SPECIAL TOOLS CHASSIS...93
SPECIAL TOOLS MOTOR...94
BLEEDING OF THE HYDRAULIC CLUTCH...96
REMOVING AND REFITTING ENGINE...98
REMOVING THE ENGINE...100
REFITTING THE ENGINE...103
CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION CABLE...105
DISASSEMBLING THE ENGINE...106
DRAIN ENGINE OIL...108
REMOVING THE ELECTRIC STARTER MOTOR...108
REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES...109
REMOVING THE OIL FILTER...109
REMOVING THE EPC WIRING HARNESS...109
REMOVING THE IGNITION (KOKUSAN 4K-2)...109
REMOVING THE IGNITION (SEM)...111
REMOVING THE IGNITION (KOKUSAN 4K-3)...111
REMOVING THE ELECTRIC STARTER DRIVE...112
REMOVING THE CYLINDER HEAD TOP SECTION...113
BLOCKING THE CRANKSHAFT...114
REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER...114
REMOVING CYLINDER HEAD...116
REMOVING CYLINDER AND PISTON...116
REMOVING ENGINE SPROCKET...117
REMOVING CLUTCH AND PRIMARY DRIVE...117
REMOVING THE OIL PUMPS...119
REMOVING THE TIMING CHAIN AND THE TIMING GEAR...120
REMOVING THE CLUTCH RELEASE SHAFT...120
PARTING OF ENGINE HOUSING...121
REMOVING THE SHIFT MECHANISM...121
REMOVING THE TRANSMISSION SHAFTS...123
REMOVING THE KICKSTARTER SHAFT...123
SERVICING INDIVIDUAL COMPONENTS...124
WORKING ON THE RIGHT HOUSING HALF...126
WORKING ON THE LEFT HOUSING HALF...128
CRANKSHAFT...129
MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY...130
CHECKING THE PISTON...130
MOUNTING INSTRUCTIONS FOR PISTON RINGS...131
PISTON RING END GAP...131
MEASURING PISTON AND CYLINDER, DETERMINING...131
CYLINDER – NIKASIL COATING...132
RECOATED CYLINDER...132
DISASSEMBLING THE CYLINDER HEAD AND CHECKING...133
DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND...134
PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION...134
CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR...135
DISASSEMBLING THE CAMSHAFT AND CHECKING THE...135
PRE-ASSEMBLING THE CAMSHAFT...135
AUTOMATIC TENSIONER...136
PREASSEMBLY OF AUTOMATIC TENSIONER...136
DISASSEMBLING THE OIL PUMPS AND CHECKING THE...136
OIL LINES (SX, SXC)...137
OIL LINES (SC)...137
OIL LINES (660 SMC MODEL 2003)...138
OIL LINES (MODELS WITH FRAME OIL)...138
OIL LINES (660 SMC FROM MODEL 2004 ON)...139
CHECKING THE KICKSTARTER COMPONENTS FOR WEAR...140
PREASSEMBLY OF KICKSTARTER SHAFT...140
CLUTCH COVER...140
REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB...140
CHECKING THE CLUTCH COMPONENTS FOR WEAR...141
CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR...142
PREASSEMBLY OF SHIFT SHAFT...142
SHIFT MECHANISM SUPPORT...143
BALANCER SHAFT...143
DISASSEMBLING AND REASSEMBLING THE WATER PUMP...143
IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION...144
ASSEMBLING THE MAIN SHAFT...144
ASSEMBLING THE COUNTER SHAFT...145
REMOVING THE INTERMEDIATE GEAR...146
CHECKING THE FREEWHEEL...146
REPLACING THE FREEWHEEL HUB...146
ELECTRIC STARTER MOTOR...146
CHECKING SECONDARY AIR SYSTEM (SLS)...147
IGNITION (KOKUSAN 4K-2)...148
CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2)...148
REPLACING THE STATOR (KOKUSAN 4K-2)...148
IGNITION (SEM)...149
CHECKING THE STATOR (SEM)...149
REPLACING THE STATOR (SEM)...149
IGNITION (KOKUSAN 4K-2)...150
CHECKING THE STATOR (KOKUSAN 4K-3)...150
REPLACING THE STATOR (KOKUSAN 4K-3)...150
ASSEMBLING THE ENGINE...152
MOUNTING THE KICKSTARTER UNIT...154
MOUNTING TRANSMISSION AND SHIFT MECHANISM...154
ADJUSTMENT OF RETURN SPRING...156
PRETENSIONING OF THE STARTER SPRING...156
MOUNTING CRANKSHAFT...156
ASSEMBLY OF ENGINE HOUSING...157
MOUNTING OIL FILTER...158
MOUNTING THE ENGINE SPROCKET...158
MOUNTING THE TIMING GEAR AND THE TIMING CHAIN...159
MOUNTING THE OIL PUMPS...159
MOUNTING THE BALANCER SHAFT AND THE PRIMARY PINION...160
MOUNTING THE CLUTCH...160
MOUNTING THE CLUTCH DISCS...161
INSTALLING THE CLUTCH RELEASE SHAFT...161
ADJUSTING THE CLUTCH RELEASE...162
MEASURE DIMENSION „Y“...162
MOUNTING PISTON AND CYLINDER...162
MOUNTING THE CYLINDER HEAD...163
MOUNTING THE CAMSHAFT, TIMING MARKS...164
MOUNTING THE WATER PUMP...165
MOUNTING THE CYLINDER HEAD TOP SECTION...166
MOUNTING THE AUTOMATIC TENSIONER...166
AUTOMATIC DECOMPRESSION TESTING...166
ADJUSTMENT OF VALVE CLEARANCE...167
MOUNTING THE CLUTCH COVER...167
MOUNTING THE ELECTRIC STARTER DRIVE...168
MOUNTING THE IGNITION (KOKUSAN 4K-2)...168
ADJUSTING THE PULSE GENERATOR (KOKUSAN 4K-2)...169
MOUNTING THE IGNITION (SEM)...169
ADJUSTMENT OF IGNITION POINT (SEM)...170
MOUNTING THE EPC WIRING HARNESS...170
MOUNTING THE IGNITION (KOKUSAN 4K-3)...171
ADJUSTMENT OF IGNITION POINT (KOKUSAN 4K-3)...171
MOUNTING THE OIL HOSES...172
MOUNTING THE CLUTCH RELEASE LEVER...172
MOUNTING THE ELECTRIC STARTER MOTOR...172
MOUNTING THE WATER HOSES...172
POURING IN ENGINE OIL...173
MOUNTING THE KICKSTARTER AND THE SHIFT LEVER...173
ELECTRICAL...174
SUPER COMPETITION 1998...180
CHECKING THE VOLTAGE REGULATOR-RECTIFIER...180
CHECKING THE VOLTAGE REGULATOR...180
CHECKING THE CAPACITOR...180
LC4 COMPETITION 1998...181
CHARGING SYSTEM...181
LEAKAGE INSPECTION...181
REMOVING THE BATTERY...182
CHARGING THE BATTERY...182
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR...182
CHECKING THE CAPACITOR...183
CHECKING THE NEUTRAL SWITCH...183
LC4 1998...184
CHARGING SYSTEM...184
LEAKAGE INSPECTION...184
REMOVING THE BATTERY...185
CHARGING THE BATTERY...185
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR...185
CHECKING THE CAPACITOR...186
ELECTRIC STARTER SYSTEM...187
CHECKING THE START AUXILIARY RELAY...188
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION...188
CHECKING THE DIODE...188
CHECKING THE STARTER RELAY...189
CHECKING THE ELECTRIC STARTER MOTOR...189
CHECKING THE CLUTCH SWITCH...190
CHECKING THE EMERGENCY OFF SWITCH...190
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM...190
IGNITION SYSTEM...191
CDI UNIT...192
CHECKING THE IGNITION COIL...192
TROUBLE SHOOTING IN THE IGNITION SYSTEM...192
EPC SYSTEM...193
DISMOUNT / RENEW SOLENOID VALVE FOR EPC...194
CHECK OF SOLENOID VALVE FOR EPC...194
CONTROLLER OF THE EPC SYSTEM...194
CHECK OF EPC SYSTEM MICROSWITCH...195
REPLACING THE EPC SYSTEM MICROSWITCH...195
CHECK OF IDLE SWITCH / CONTACT SCREWS...195
DUKE-E 1998...196
CHARGING SYSTEM...196
LEAKAGE INSPECTION...196
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR...197
REMOVING THE BATTERY...197
CHARGING THE BATTERY...197
CHECKING THE CAPACITOR...198
ELECTRIC STARTER SYSTEM...199
CHECKING THE START AUXILIARY RELAY...200
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION...200
CHECKING THE DIODES...201
CHECKING THE CLUTCH SWITCH...201
CHECKING THE EMERGENCY OFF SWITCH...201
CHECKING THE STARTER RELAY...202
CHECKING THE ELECTRIC STARTER MOTOR...202
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM...202
IDLE SWITCH...202
IGNITION SYSTEM...203
CDI UNIT...204
CHECKING THE IGNITION COIL...204
SPARK PLUG CONNECTOR...204
CHECKING THE SIDE STAND RELAY...204
CHECKING THE SIDE STAND SWITCH...205
TROUBLE SHOOTING IN THE IGNITION SYSTEM...205
SXC 1999...206
CHECKING THE VOLTAGE REGULATOR...206
CHECKING THE CAPACITOR...206
SC 1999...207
CHECKING THE VOLTAGE REGULATOR...207
CHECKING THE CAPACITOR...207
CHECKING THE IGNITION COIL...207
DUKE 1999...208
CHARGING SYSTEM...208
LEAKAGE INSPECTION...208
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR...209
REMOVING THE BATTERY...209
CHARGING THE BATTERY...209
CHECKING THE CAPACITOR...210
ELECTRIC STARTER SYSTEM...211
CHECKING THE START AUXILIARY RELAY...212
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION...212
CHECKING THE DIODES...213
CHECKING THE CLUTCH SWITCH...213
CHECKING THE EMERGENCY OFF SWITCH...213
CHECKING THE STARTER RELAY...214
CHECKING THE ELECTRIC STARTER MOTOR...214
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM...214
CHECKING THE IDLE SWITCH...214
IGNITION SYSTEM...215
CDI UNIT...216
CHECKING THE IGNITION COIL...216
SPARK PLUG CONNECTOR...216
CHECKING THE SIDE STAND RELAY...216
CHECKING THE SIDE STAND SWITCH...217
TROUBLE SHOOTING IN THE IGNITION SYSTEM...217
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...218
DYNAMIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE...218
STATIC IGNITION VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE...220
STATIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE...222
STATIC IGNITION VALUES 400/620/625 SC, 660 SMC...224
STATIC GENERATOR VALUES 400/620/625 SC, 660 SMC...226
CHECKING SPEEDOMETER AND SPEEDOMETER SENSOR...227
FUEL SYSTEM...228
MIKUNI BST 40...232
PART-LOAD SYSTEM...233
FULL-LOAD SYSTEM...234
DISASSEMBLING THE CARBURETOR...235
ASSEMBLING THE CARBURETOR...237
CHECKING/ADJUSTING THE THROTTLE SENSOR...238
ADJUST IDLING SPEED...239
ADJUSTING THE THROTTLE CABLE...239
CHECK FLOAT LEVEL...239
DELL’ORTO...240
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD)...241
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD)...242
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND)...245
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND)...247
DISASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS)...250
ASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS)...251
CHECK FLOAT LEVEL (DELL’ORTO 38 ND / 40 SD)...254
CHECKING AXIAL CLEARANCE OF FLOAT (DELL’ORTO 38 ND / 40 SD)...254
ADJUST HOT START DEVICE (DELL’ORTO 40 SD)...254
ADJUSTING THE THROTTLE CABLE...255
ADJUSTING THE CHOKE CABLE...255
KEIHIN FCR 41...256
DISASSEMBLING THE CARBURETOR...257
CHECKING THE CHOKE SLIDE...260
CHECKING THE ACCELERATOR PUMP...260
CHECKING THE JET NEEDLE...260
CHECKING THE FLOAT NEEDLE VALVE...260
CHECKING THE THROTTLE VALVE...260
ASSEMBLING THE CARBURETOR...261
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...264
CHECKING THE THROTTLE VALVE SENSOR...265
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...265
ADJUST IDLING SPEED...266
CHECKING/ADJUSTING THE FLOAT HEIGHT...228
KEIHIN FCR 41...268
DISASSEMBLING THE CARBURETOR...269
CHECKING THE CHOKE SLIDE...272
CHECKING THE ACCELERATOR PUMP...272
CHECKING THE JET NEEDLE...272
CHECKING THE FLOAT NEEDLE VALVE...272
CHECKING THE THROTTLE VALVE...272
ASSEMBLING THE CARBURETOR...273
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...276
CHECKING THE THROTTLE VALVE SENSOR...277
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...277
ADJUST IDLING SPEED...278
CHECKING/ADJUSTING THE FLOAT HEIGHT...278
TROUBLE SHOOTING...280
SX, SXC, SC, SMC)...282
LC4 COMPETITION...284
LC4...287
CHASSIS...290
DISMOUNTING/MOUNTING THE CHASSIS COMPONENTS...290
DISMOUNTING/MOUNTING THE ROCKER ARM AND SHOCK ABSORBER...292
DISMOUNTING/MOUNTING THE FORK LEGS...293
DISMOUNTING/MOUNTING THE SWING ARM...293
OVERHAULING THE CHASSIS COMPONENTS...290
REPLACING THE SWING ARM SUPPORT...294
REPLACING THE STEERING HEAD BEARING...295
REPLACING THE CHAIN, REAR SPROCKETS AND CHAIN GUIDES...296
REPLACING THE FRONT WHEEL BEARINGS...297
REPLACING THE REAR WHEEL BEARINGS...297
OVERHAULING THE ROCKER ARM...298
REPLACING THE LINKAGE BOLT BEARING IN THE FRAME...298
CUTTING AND RIVETING THE CHAIN (FROM MODEL 2005 ON)...299
TECHNICAL SPECIFICATIONS...300
MODEL 1998...300
ENGINE 400/540 SXC...304
CHASSIS 400/540 SXC...305
ENGINE 400/620 SX, SC...306
CHASSIS 400/620 SX, SC...307
ENGINE 620 LC4 COMPETITION...308
CHASSIS 620 LC4 COMPETITION...309
ENGINE 400/540 SXC...310
CHASSIS 400/640 LC4...312
CHASSIS 640 ADVENTURE-R...313
CHASSIS 640 DUKE-E...314
MODEL 1999...300
ENGINE 400/540 SXC, 620 SX...315
CHASSIS 400/540 SXC, 620 SX...316
ENGINE 400/620 SC...317
CHASSIS 400/620 SC...318
ENGINE 620 LC4 COMPETITION...319
CHASSIS 620 LC4 COMPETITION...320
ENGINE 400/640 LC4...321
CHASSIS 400/640 LC4...322
ENGINE 640 ADVENTURE-R...323
CHASSIS 640 ADVENTURE-R...324
ENGINE 640 DUKE...325
CHASSIS 640 DUKE...326
MODEL 2000...300
ENGINE SC, SUPERMOTO...327
CHASSIS SC, SUPERMOTO...328
ENGINE LC4-E, ADVENTURE, DUKE...329
CHASSIS LC4-E SUPERMOTO...331
CHASSIS 640 ADVENTURE-R...332
CHASSIS 640 DUKE...333
CHASSIS 640 DUKE AUS...334
ENGINE 400 SXC...335
CHASSIS 400/540 SXC...336
MODEL 2001...302
ENGINE 620 SC, SUPERMOTO...337
CHASSIS 620 SC, SUPERMOTO...338
ENGINE LC4-E, ADVENTURE, DUKE...339
CHASSIS LC4-E, SUPERMOTO...341
CHASSIS 640 LC4 ADVENTURE...342
CHASSIS 640 DUKE...343
CHASSIS 640 DUKE USA, AUS...344
MODEL 2002...302
ENGINE 625 SC, SUPERMOTO...345
CHASSIS 625 SC, SUPERMOTO...346
ENGINE 640 LC4, ADVENTURE, DUKE...347
CHASSIS 640 LC4, SUPERMOTO...348
CHASSIS 640 ADVENTURE...349
CHASSIS 640 DUKE...350
MODEL 2003...302
ENGINE 625 SXC...351
CHASSIS 625 SXC...352
ENGINE 640 LC4, ADVENTURE, DUKE...353
CHASSIS 640 LC4, SUPERMOTO...354
CHASSIS 640 LC4 ADVENTURE...355
CHASSIS 640 DUKE...356
ENGINE 660 SMC...357
CHASSIS 660 SMC...358
MODEL 2004...302
ENGINE 625 SXC USA...359
ENGINE 625 SXC EUR...360
CHASSIS 625 SXC...361
ENGINE 640 LC4, ADVENTURE, DUKE...362
CHASSIS 640 LC4, SUPERMOTO...363
CHASSIS 640 LC4 ADVENTURE...364
CHASSIS 640 DUKE...365
ENGINE 660 SMC...366
CHASSIS 660 SMC...367
MODEL 2005...303
ENGINE 625 SXC / SMC...368
CHASSIS 625 SXC / SMC...369
ENGINE 640 LC4, ADVENTURE, DUKE...370
CHASSIS 640 LC4, SUPERMOTO...371
CHASSIS 640 ADVENTURE...372
CHASSIS 640 DUKE...373
ENGINE 660 SMC...374
CHASSIS 660 SMC...375
TIGHTENING TORQUES...303
ENGINE...376
CHASSIS...377
ASSEMBLY CLEARANCE, WEAR LIMIT...378
PERIODIC MAINTENANCE SCHEDULE...380
MODEL 1998...380
SX, SXC, SC...382
LC4 COMPETITION, LC4...383
ADVENTURE-R...384
DUKE...385
MODEL 1999...380
SX, SXC, SC...386
LC4 COMPETITION, LC4...387
ADVENTURE-R...388
DUKE...390
MODEL 2001...380
620 SC...391
LC4-E, ADVENTURE...393
DUKE...395
MODEL 2002...380
625 SC...397
LC4, ADVENTURE...399
DUKE...401
MODEL 2003...380
625 SXC, 660 SMC...403
640 LC4, 640 LC4 ADVENTURE...405
DUKE...407
MODEL 2004...380
625 SXC USA...409
625 SXC EUR...411
640 LC4, 640 LC4 ADVENTURE...413
660 SMC...415
DUKE II...417
MODEL 2005...381
625 SXC / SMR...419
640 LC4, 640 LC4 SUPERMOTO ...421
640 LC4 ADVENTURE...423
640 DUKE...425
660 SMC...427
WIRING DIAGRAMS...430
MODEL1998...430
400 / 540 SXC...435
400 / 620 SC (For Competition)...437
400 / 620 SC (For Australia)...439
400 / 620 SC (For Germany)...441
640 LC4 (For USA)...443
640 ADVENTURE-R (Dell Orto)...445
640 DUKE-E...447
620 LC4 COMPETITION...449
400 LC4...451
640 LC4...453
MODEL1999...430
400 / 540 SXC...455
400 / 540 SXC (Australia)...457
400 / 620 SC...459
400 / 620 SC (Australia)...461
640 ADVENTURE-R (Dell Orto)...445
640 ADVENTURE-R (Mikuni)...463
640 DUKE...465
620 LC4 COMPETITION...449
400 LC4...451
640 LC4, SUPERMOTO...453
640 LC4 (USA)...443
MODEL2000...430
400 / 620 SC / 620 SC SUPERMOTO...459
640 ADVENTURE-R...463
640 DUKE...465
400 LC4-E...451
640 LC4-E, SUPERMOTO...453
400 / 640 LC4-E (USA)...467
MODEL2001...431
620 SC / 620 SC SUPERMOTO...469
640 LC4 ADVENTURE...471
640 DUKE...473
400 LC4-E, 400 / 640 LC4-E USA...475
640 LC4-E, SUPERMOTO...477
MODEL2002...431
625 SC / 625 SC SUPERMOTO...479
640 LC4 ADVENTURE...481
640 DUKE...483
640 LC4, 640 LC4 SUPERMOTO...485
640 LC4, 640 LC4 SUPERMOTO USA...487
MODEL2003/04...431
660 SMC (2003)...489
625 SXC (2003/04)...491
640 LC4, 640 LC4 SUPERMOTO (2003/04)...493
640 LC4 ADVENTURE (2003/04)...495
640 DUKE (2003/04)...505
660 SMC (2004)...515
MODEL 2005...431
625 SXC 2005...516
625 SMC...525
640 LC4...534
640 LC4 SUPERMOTO...544
640 LC4 ADVENTURE...495
640 DUKE...505
660 SMC...554
660 RALLY...561
EXPLANATION OF CONNECTORS, CABLE COLORS...566
DETAIL WIRING DIAGRAMS...432
640 LC4 ADVENTURE 2003-2005...432
SWITCHES...496
START SYSTEM...497
CHARGING SYSTEM...498
ECU...499
FLASHER, HORN, COOLING FAN...500
LIGHTS...501
INSTRUMENTS...502
GROUND CONNECTION...503
POSITIVE CONNECTION...504
640 DUKE 2003-2005...432
SWITCHES...506
START SYSTEM...507
CHARGING SYSTEM...508
ECU...509
FLASHER, HORN, COOLING FAN...510
LIGHTS...511
INSTRUMENTS...512
GROUND CONNECTION...513
POSITIVE CONNECTION...514
625 SXC 2005...432
SWITCHES...517
START-/CHARGING SYSTEM...518
ECU...519
FLASHER, HORN...520
LIGHTS...521
INSTRUMENTS...522
GROUND CONNECTION...523
POSITIVE CONNECTION...524
625 SMC 2005...433
SWITCHES...526
START-/CHARGING SYSTEM...527
ECU...528
FLASHER, HORN...529
LIGHTS...530
INSTRUMENTS...531
GROUND CONNECTION...532
POSITIVE CONNECTION...533
640 LC4 2003-2005...433
SWITCHES...535
START SYSTEM...536
CHARGING SYSTEM...537
ECU...538
FLASHER, HORN, COOLING FAN...539
LIGHTS...540
INSTRUMENTS...541
GROUND CONNECTION...542
POSITIVE CONNECTION...543
640 LC4 SUPERMOTO 2005...433
SWITCHES...545
START SYSTEM...546
CHARGING SYSTEM...547
ECU...548
FLASHER, HORN, COOLING FAN...549
LIGHTS...550
INSTRUMENTS...551
GROUND CONNECTION...552
POSITIVE CONNECTION...553
660 SMC 2005...434
SWITCHES...555
CDI, CHARGING SYSTEM...556
LIGHTS, INSTRUMENTS, HORN...557
FLASHER...558
POSITIVE CONNECTION...559
GROUND CONNECTION...560
660 RALLY 2003-2005...434
SWITCHES...562
GROUND CONNECTION...563
POSITIVE CONNECTION...564
FLASHER...565
KTM 400, 450, 520, 530, 540, 620, 625, 640,660 EXC/LC4/SC/SMC/SX/XC/Adventure/Duke/Supermoto Repair Service Manual 1998-2009
