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400-660 LC4

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

Art.Nr.: 3.206.024-E

REPAIRMANUAL1998-2005

Important Information/Updating Instructions7
Introduction11
Reply Fax for Repair Manuals13
General Information15
Index15
Changing the Engine Oil (Models Without Frame Oil)17
Changing the Oil Filter17
Changing the Microfilter18
Oil Circuit19
Oil Circuit 660 SMC (Model 2003)20
Changing the Engine Oil (Models with Frame Oil)21
Changing the Fine Screen Filter21
Changing the Oil Filter22
Oil Circuit23
Oil Circuit (660 SMC from Model 2004 On)24
Functional Characteristics of the Secondary Air System (SLS)25
Mode of Operation of the Secondary Air System SAS (Starting with the 2004 Model)26
Electronic Power Control System (EPC)27
Special Tools - Chassis28
Special Tools Motor29
Checking the Oil Level of the Hydraulic Clutch31
Bleeding of the Hydraulic Clutch31
Removing and Refitting Engine33
Removing the Engine35
Mounting the Engine38
Checking the Adjustment of the Hand Decompression Cable40
Disassembling the Engine41
Drain Engine Oil43
Removing the Electric Starter Motor43
Removing the Clutch Release Lever and the Oil Hoses44
Removing the Oil Filter44
Removing the EPC Wiring Harness44
Removing the Ignition (Kokusan 4K-2)44
Removing the Ignition (SEM)46
Removing the Ignition (Kokusan 4K-3)46
Removing the Electric Starter Drive47
Removing the Cylinder Head Top Section48
Blocking the Crankshaft49
Removing Cylinder Head51
Removing Cylinder and Piston51
Removing Engine Sprocket52
Removing Clutch and Primary Drive52
Removing the Oil Pumps54
Removing the Timing Chain and the Timing Gear55
Removing the Clutch Release Shaft55
Parting of Engine Housing56
Removing the Shift Mechanism56
Removing the Transmission Shafts58
Removing the Kickstarter Shaft58
Servicing on Individual Components59
Working on the Right Housing Half61
Working on the Left Half of the Housing63
Crankshaft64
Measuring and Adjusting of Crankshaft Axial Clearance65
Checking the Piston65
Mounting Instructions for Piston Rings66
Piston Ring End Gap66
Measuring Piston and Cylinder, Determining the Piston Fitting Clearance66
Cylinder – Nikasil Coating67
Recoated Cylinder67
Disassembling the Cylinder Head and Checking the Components for Wear68
Disassembling the Cylinder Head Top Section and Checking the Components for Wear69
Pre-Assembling the Cylinder Head Top Section69
Checking the Components of the Timing Mechanism for Wear70
Disassembling the Camshaft and Checking the Components for Wear70
Preassembling the Camshaft70
Automatic Tensioner71
Preassembly of Automatic Tensioner71
Disassembling the Oil Pumps and Checking the Components for Wear71
Oil Lines (SX, SXC)72
Oil Lines (SC)72
Oil Lines (660 SMC Model 2003)73
Oil Lines (Models with Frame Oil)73
Oil Lines (625/640 from Modell 2005, 660 SMC from Modell 2004)74
Checking the Kickstarter Components for Wear75
Preassembly of Kickstarter Shaft75
Clutch Cover75
Replacing Absorbing Elements of the Outer Clutch Hub75
Checking the Clutch Components for Wear76
Checking the Shift Mechanism Components for Wear77
Preassembly of Shift Shaft77
Shift Mechanism Support78
Balancer Shaft78
Disassembling and Reassembling the Water Pump78
Important Note Regards Working on Transmission79
Assembling the Main Shaft79
Assembling the Counter Shaft80
Removing the Intermediate Gear81
Checking the Freewheel81
Replacing the Freewheel Hub81
Electric Starter Motor81
Checking the SAS Valve82
Ignition (Kokusan 4K2)83
Checking the Stator and the Pulse Generator (Kokusan 4K2)83
Replacing the Stator (Kokusan 4K2)83
Ignition (SEM)84
Checking the Stator (SEM)84
Replacing the Stator (SEM)84
Ignition (Kokusan 4K-3)85
Checking the Stator (Kokusan 4K-3)85
Installing a New Stator (Kokusan 4K-3)85
Assembling the Engine87
Mounting the Kickstarter Unit89
Mounting Transmission and Shift Mechanism89
Adjustment of Return Spring91
Pretensioning of the Starter Spring91
Mounting Crankshaft91
Assembly of Engine Housing92
Mounting Oil Filter93
Mounting the Engine Sprocket93
Mount the Timing Gear and the Timing Chain94
Mounting the Oil Pumps94
Mounting the Balancer Shaft and the Primary Pinion95
Mounting the Clutch95
Mounting the Clutch Discs96
Installing the Clutch Release Shaft96
Adjusting the Clutch Release97
Measure the Dimension „Y" (from Model 2003 On)97
Mounting Piston and Cylinder97
Push Rod97
Mounting the Cylinder Head98
Mounting the Camshaft, Timing Marks99
Mounting the Water Pump100
Mounting the Cylinder Head Top Section101
Mounting the Automatic Tensioner101
Automatic Decompression Testing101
Adjustment of Valve Clearance102
Mounting the Clutch Cover102
Mounting the Electric Starter Drive103
Mounting the Ignition (Kokusan 4K-2)103
Adjusting the Pulse Generator104
Mounting the Ignition (SEM)104
Adjustment of Ignition Point (SEM)105
Mounting the EPC Wiring Harness105
Installing the Ignition (Kokusan 4K-3)106
Adjusting the Ignition Point (Kokusan 4K-3)106
Mounting the Oil Hoses107
Mounting the Clutch Release Lever107
Mounting the Electric Starter Motor107
Mounting the Water Hoses107
Pouring in Engine Oil108
Mounting the Kickstarter and the Shift Lever108
Electrical109
Electrical - Super Competition115
Checking the Voltage Regulator-Rectifier115
Checking the Voltage Regulator115
Checking the Capacitor115
Electrical - LC4 Competition116
Charging System116
Leakage Inspection116
Removing the Battery117
Charging the Battery117
Charging Voltage / Checking the Voltage Regulator-Rectifier117
Checking the Neutral Switch118
Electrical - LC4119
Electric Starter System122
Check Start Auxiliary Relay123
Checking the Auxiliary Starting Relay for Faultless Operation123
Checking the Diode123
Checking the Starter Relay124
Checking the Electric Starter Motor124
Checking the Clutch Switch125
Checking the Tip Switch and the Emergency off Switch125
Trouble Shooting in the Electric Starter System125
Ignition System126
CDI Unit127
Checking the Ignition Coil127
Trouble Shooting in the Ignition System127
EPC System128
Dismount / Renew Solenoid Valve for EPC129
Check of Solenoid Valve for EPC129
Controller of the EPC System129
Check of EPC System Microswitch130
Replacing the EPC System Microswitch130
Check of Idle Switch / Contact Screws130
Electrical - Duke-E131
Checking the Diodes136
Checking the Side Stand Switch140
Electrical - SXC '99141
Electrical - SC '99142
Checking the Voltage Regulator (Kokusan)142
Electrical - Duke '99143
Dynamic Generator Values 400/600 LC4-E / 625 SXC (Kokusan 4K-2)153
Measuring Conditions153
Schematic Diagram154
Static Ignition Values 400/640 LC4-E / 625 SXC (Kokusan 4K-2)155
Static Generator Values 400/640 LC4-E / 625 SXC (Kokusan 4K-2)157
Static Ignition Values 400/620/625 SC / 660 SMC (Kokusan 4K-3, 3C)159
Static Generator Values 400/620/625 SC / 660 SMC (Kokusan 4K-3, 3C)161
Checking the Speedometer Sensor and the Speedometer (Adventure – from the 2002 Model)162
Checking the Speedometer Sensor162
Fuel System163
Carburetor - Mikuni BST 40167
Part-Load System (Mikuni BST 40)168
Full-Load System (Mikuni BST 40)169
Disassembling the Carburetor (Mikuni BST-40)170
Assembling the Carburetor (Mikuni BST 40)172
Checking the Throttle Sensor (from Model 2003 On)173
Adjusting the Throttle Sensor173
Adjust Idling Speed174
Adjusting the Throttle Cable174
Check Float Level174
Carburetor - Dell'orto PHM 40 SD175
Disassembling the Carburetor (Dell’orto PHM 40 SD)176
Assembling the Carburetor (Dell’orto PHM 40 SD)177
Carburetor - Dell'orto PHM 38 ND179
Disassembling the Carburetor (Dell’orto PHM 38 ND)180
Assembling the Carburetor (Dell’orto PHM 38 ND)182
Carburetor - Dell'orto VHSB 38 QS184
Disassembling the Carburetor (Dell’orto VHSB 38 QS)185
Assembling the Carburetor (VHSB 38 QS)186
Idling Range – a188
Opening up – B188
Part-Throttle Range – C188
Full Throttle Range – D188
Check Float Level (Dell’orto PHM 38ND / 40SD)189
Checking Axial Play of Float (Dell’orto PHM 38ND / 40SD)189
Adjust Hot Start Device (Dell’orto PHM 40SD)189
Adjusting the Choke Cable190
Carburetor - Keihin FCR 41191
Disassembling the Carburetor192
Checking the Choke Slide195
Checking the Accelerator Pump195
Checking the Jet Needle195
Checking the Float Needle Valve195
Assembling the Carburetor196
Adjusting the Position of the Throttle Valve Sensor199
Checking the Throttle Valve Sensor200
Dismounting and Installing the Throttle Valve Sensor200
Adjust Idling201
Adjusting the Mixture Control Screw202
Carburetor - Keihin FCR-MX 41203
Disassembling the Carburetor Keihin FCR - MX 41204
Checking the Choke Slide and Hot Start Knob207
Checking the Throttle Valve207
Assembling the Carburetor Keihin FCR-MX 41208
CARBURETOR – Adjust Idling (Keihin FCR-MX 41)213
Checking the Float Level (Float Height)213
Trouble Shooting215
Trouble Shooting - SX, SXC, SC, SMC217
Trouble Shooting - LC4 Competition219
Trouble Shooting LC4222
Chassis225
Dismounting/Mounting the Rocker Arm and Shock Absorber227
Dismounting/Mounting the Fork Legs228
Dismounting/Mounting the Swing Arm228
Replacing the Swing Arm Bearing229
Replacing the Steering Head Bearing230
Replacing the Chain, Chain Guide, Pinion and Rear Sprocket231
Replacing the Front Wheel Bearing232
Replacing the Rear Wheel Bearing232
Overhauling the Rocker Arm233
Replacing the Linkage Bolt Bearing in the Frame233
Opening the Chain with a Separating/Rivet Tool234
Riveting the Chain234
Technical Specifications235
Engine 400/540 SXC '98239
Basic Carburetor Setting239
Chassis 400/540 SXC '98240
Standard Adjustment - Fork240
Standard Adjustment - Shock Absorber240
Engine 400/620 SX, SC '98241
Chassis 400/620 SX, SC '98242
Engine 620 LC4 Competition '98243
Chassis 620 LC4 Comp. '98244
Engine 400/640 LC4 '98245
Chassis 400/640 LC4 '98247
Chassis 640 Adventure R '98248
Chassis KTM 640 Duke-E '98249
Engine 400/540 SXC, 620 SX '99250
Chassis 400/540 SXC, 620 SX '99251
Engine 400/620 Supercompetition '99252
Chassis 400/620 Supercompetition '99253
Engine 620 LC4 Competition '99254
Chassis 620 LC4 Competition '99255
Engine 400/640 LC4 '99256
Chassis 400 LC4 / 640 LC4 / Supermoto '99257
Engine 640 LC4-E Adventure R '99258
Chassis 640 Adventure R '99259
Engine KTM 640 Duke '99260
Chassis KTM 640 Duke '99261
400/620 SC, Supermoto 2000262
Chassis 400/620 SC, Supermoto 2000263
Engine 400/640 LC4-E, 640 Adventure, Duke 2000264
Chassis 400/640 LC4-E, 640 LC4-E Supermoto 2000266
Chassis LC4 Adventure R 640 2000267
Chassis KTM 640 Duke 2000268
Chassis 640 Duke 2000 USA, aus269
Engine 400 SXC USA 2000270
Chassis 400 SXC USA 2000271
Engine 620 SC, 620 SC Supermoto 2001272
Chassis 620 SC, 620 SC Supermoto 2001273
Engine 400/640 LC4-E, 640 Adventure, Duke 2001274
Chassis 400/640 LC4-E, 640 LC4-E Supermoto 2001276
Chassis 640 LC4 Adventure277
Chassis KTM 640 Duke 2001278
Chassis 640 Duke 2001 USA, aus279
Engine 625 SC, 625 SC Supermoto 2002280
Chassis 625 SC, 625 SC Supermoto 2002281
Engine 640 LC4 2002282
Chassis 640 LC4, 640 LC4 Supermoto 2002283
Chassis 640 Duke II 2002285
Engine 625 SXC 2003286
Chassis 625 SXC 2003287
Engine 640 LC4, 640 LC4 Supermoto 2003288
Cassis 640 LC4, 640 LC4 Supermoto 2003289
Chassis 640 LC4 Adventure 2003290
Chassis 640 Duke II 2003291
Engine 660 SMC 2003292
Chassis 660 SMC 2003293
Engine 625 SXC USA 2004294
Engine 625 SXC Europe 2004295
Chassis 625 SXC 2004296
Engine 640 LC4, 640 LC4 Supermoto 2004297
Chassis 640 LC4, 640 LC4 Supermoto 2004298
Chassis 640 LC4 Adventure 2004299
Chassis 640 Duke II 2004300
Engine 660 SMC 2004301
Chassis 660 SMC 2004302
Engine 625 SXC / SMC 2005303
Chassis 625 SXC / SMC 2005304
Engine 640 LC4, Adventure, Duke 2005305
Chassis 640 LC4 2005306
Chassis 640 LC4 Adventure 2005307
Chassis 640 Duke 2005308
Engine 660 SMC 2005309
Chassis 660 SMC 2005310
Tightening Torque - Engine311
Tightening Torque - Chassis312
Assembly Clearance, Wear Limit313
Periodic Maintenance Schedule315
Vital Checks and Care Procedures to be Conducted by the Owner or the Mechanic327
Wiring Diagrams365
400/540 Sxc '98370
400/620 Sc '98372
640 Lc4 '99378
640 Adventure '98/'99380
640 Duke-E '98382
620 LC4 Competition '98384
400 Lc4-E '98 '99 2000386
640 Lc4-E '2000388
400/540 Sxc '99390
400/620 Sc '99-2000394
400-620 Sc '99396
640 Adventure 99-2000398
Duke 2000400
400/640 Lc4402
620 Supercomp 2001404
Mikuni Vergaser 640 Adventure 2001406
Duke 2001408
400 Lc4-E 2001410
640 Lc4-E 2001412
625 Supercomp 2002414
640 LC4 Adventure416
Duke 2002418
400/640 Lc4-E 2002420
640 Lc4-E Usa 2002422
660 Smc 2003424
625 Sxc 2003-04426
400/640 Lc4-E 2003-04428
LC4 Adventure 03-06430
Adventure 03-06432
Charging Circuit433
Ecu434
Turn Indicator System435
Light-Brake System436
Instruments437
Ground Connection438
Positive Connection439
640-Duke 03-06 Wiring Diagram440
Start System442
640-Duke 03-06 Charging Circuit443
640-Duke 03-06 ECU444
640-Duke 03-06 Turn Indicator System445
640-Duke 03-06 Light-Brake System446
640-Duke 03-06 Instruments Tachometer447
640-Duke 03-06 Ground Connection448
640-Duke 03-06 Positive Connection449
660 SMC 2004 Wiring Diagram450
625 SXC 2005-06 Wiring Diagram451
Start - Charging System453
625 Sxc 05-06 Ecu454
625 SXC 05-06 Turn Indicator System455
625 SXC 05-06 Light-Brake System456
625 SXC 05-06 Instruments457
625 SXC 05-06 Ground Connection458
625 SXC 05-06 Positive Connection459
625 SMC 2005-06 Wiring Diagram460
625 SMC 05-06 Start - Charging System462
625 Smc 05-06 Ecu463
625 SMC 05-06 Turn Indicator System464
625 SMC 05-06 Light-Brake System465
625 SMC 05-06 Instruments466
625 SMC 05-06 Ground Connection467
625 SMC 05-06 Positive Connection468
LC4-E 03-06 Wiring Diagram469
LC4-E 03-06 Start System471
LC4-E 03-06 Charging Circuit472
Lc4-E 03-06 Ecu473
LC4-E 03-06 Turn Indicator System474
LC4-E 03-06 Light-Brake System475
LC4-E 03-06 Instruments476
LC4-E 03-06 Ground Connections477
LC4-E 03-06 Positive Connection478
LC4-640 SM 2005-06 Wiring Diagram479
640 SM 05-06 Start System481
640 SM 05-06 Charging Circuit482
640 Sm 05-06 Ecu483
640 SM 05-06 Turn Indicator System484
640 SM 05-06 Light-Brake System485
640 SM 05-06 Instruments486
640 SM 05-06 Ground Connection487
640 SM 05-06 Positive Connection488
660 SMC 2005-06 Wiring Diagram489
660 SMC 2005-06 CDI - Charging Circuit491
660 SMC 2005-06 Light System - Instruments492
660 SMC 2005-06 Turn Indicator System493
660 SMC 2005-06 Positive Connection494
660 SMC 2005-06 Ground Connection495
LC4-Rally 2003-06 Wiring Diagram496
LC4-Rally Ground Connection498
LC4-Rally Positive Connection499
LC4-Rally Flasher System500

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KTM 400-660 LC4 1998-2005 Specifications

General

Brand	KTM
Model	400-660 LC4 1998-2005
Category	Engine
Language	English

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KTM 400-660 LC4 1998-2005 User Manual

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KTM 400-660 LC4 1998-2005 Specifications

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