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400-660 LC4 1998-2005
KTM 400-660 LC4 1998-2005 User Manual
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Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
Removing the electric starter drive
–
Pull the reduction gear
1
off the bearing bolt.
–
Remove both needle bearings
2
and pull the bearing bolt
3
out of
the engine housing.
–
Remove the freewheel gear
4
and the needle bearing
5
.
4-6E
1
2
3
4
5
46
48
Table of Contents
Important Information/Updating Instructions
7
Introduction
11
Reply Fax for Repair Manuals
13
General Information
15
Index
15
Changing the Engine Oil (Models Without Frame Oil)
17
Changing the Oil Filter
17
Changing the Microfilter
18
Oil Circuit
19
Oil Circuit 660 SMC (Model 2003)
20
Changing the Engine Oil (Models with Frame Oil)
21
Changing the Fine Screen Filter
21
Changing the Oil Filter
22
Oil Circuit
23
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 - Chassis
28
Special Tools Motor
29
Checking the Oil Level of the Hydraulic Clutch
31
Bleeding of the Hydraulic Clutch
31
Removing and Refitting Engine
33
Removing the Engine
35
Mounting the Engine
38
Checking the Adjustment of the Hand Decompression Cable
40
Disassembling the Engine
41
Drain Engine Oil
43
Removing the Electric Starter Motor
43
Removing the Clutch Release Lever and the Oil Hoses
44
Removing the Oil Filter
44
Removing the EPC Wiring Harness
44
Removing the Ignition (Kokusan 4K-2)
44
Removing the Ignition (SEM)
46
Removing the Ignition (Kokusan 4K-3)
46
Removing the Electric Starter Drive
47
Removing the Cylinder Head Top Section
48
Blocking the Crankshaft
49
Removing Cylinder Head
51
Removing Cylinder and Piston
51
Removing Engine Sprocket
52
Removing Clutch and Primary Drive
52
Removing the Oil Pumps
54
Removing the Timing Chain and the Timing Gear
55
Removing the Clutch Release Shaft
55
Parting of Engine Housing
56
Removing the Shift Mechanism
56
Removing the Transmission Shafts
58
Removing the Kickstarter Shaft
58
Servicing on Individual Components
59
Working on the Right Housing Half
61
Working on the Left Half of the Housing
63
Crankshaft
64
Measuring and Adjusting of Crankshaft Axial Clearance
65
Checking the Piston
65
Mounting Instructions for Piston Rings
66
Piston Ring End Gap
66
Measuring Piston and Cylinder, Determining the Piston Fitting Clearance
66
Cylinder – Nikasil Coating
67
Recoated Cylinder
67
Disassembling the Cylinder Head and Checking the Components for Wear
68
Disassembling the Cylinder Head Top Section and Checking the Components for Wear
69
Pre-Assembling the Cylinder Head Top Section
69
Checking the Components of the Timing Mechanism for Wear
70
Disassembling the Camshaft and Checking the Components for Wear
70
Preassembling the Camshaft
70
Automatic Tensioner
71
Preassembly of Automatic Tensioner
71
Disassembling the Oil Pumps and Checking the Components for Wear
71
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 Wear
75
Preassembly of Kickstarter Shaft
75
Clutch Cover
75
Replacing Absorbing Elements of the Outer Clutch Hub
75
Checking the Clutch Components for Wear
76
Checking the Shift Mechanism Components for Wear
77
Preassembly of Shift Shaft
77
Shift Mechanism Support
78
Balancer Shaft
78
Disassembling and Reassembling the Water Pump
78
Important Note Regards Working on Transmission
79
Assembling the Main Shaft
79
Assembling the Counter Shaft
80
Removing the Intermediate Gear
81
Checking the Freewheel
81
Replacing the Freewheel Hub
81
Electric Starter Motor
81
Checking the SAS Valve
82
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 Engine
87
Mounting the Kickstarter Unit
89
Mounting Transmission and Shift Mechanism
89
Adjustment of Return Spring
91
Pretensioning of the Starter Spring
91
Mounting Crankshaft
91
Assembly of Engine Housing
92
Mounting Oil Filter
93
Mounting the Engine Sprocket
93
Mount the Timing Gear and the Timing Chain
94
Mounting the Oil Pumps
94
Mounting the Balancer Shaft and the Primary Pinion
95
Mounting the Clutch
95
Mounting the Clutch Discs
96
Installing the Clutch Release Shaft
96
Adjusting the Clutch Release
97
Measure the Dimension „Y" (from Model 2003 On)
97
Mounting Piston and Cylinder
97
Push Rod
97
Mounting the Cylinder Head
98
Mounting the Camshaft, Timing Marks
99
Mounting the Water Pump
100
Mounting the Cylinder Head Top Section
101
Mounting the Automatic Tensioner
101
Automatic Decompression Testing
101
Adjustment of Valve Clearance
102
Mounting the Clutch Cover
102
Mounting the Electric Starter Drive
103
Mounting the Ignition (Kokusan 4K-2)
103
Adjusting the Pulse Generator
104
Mounting the Ignition (SEM)
104
Adjustment of Ignition Point (SEM)
105
Mounting the EPC Wiring Harness
105
Installing the Ignition (Kokusan 4K-3)
106
Adjusting the Ignition Point (Kokusan 4K-3)
106
Mounting the Oil Hoses
107
Mounting the Clutch Release Lever
107
Mounting the Electric Starter Motor
107
Mounting the Water Hoses
107
Pouring in Engine Oil
108
Mounting the Kickstarter and the Shift Lever
108
Electrical
109
Electrical - Super Competition
115
Checking the Voltage Regulator-Rectifier
115
Checking the Voltage Regulator
115
Checking the Capacitor
115
Electrical - LC4 Competition
116
Charging System
116
Leakage Inspection
116
Removing the Battery
117
Charging the Battery
117
Charging Voltage / Checking the Voltage Regulator-Rectifier
117
Checking the Neutral Switch
118
Electrical - LC4
119
Electric Starter System
122
Check Start Auxiliary Relay
123
Checking the Auxiliary Starting Relay for Faultless Operation
123
Checking the Diode
123
Checking the Starter Relay
124
Checking the Electric Starter Motor
124
Checking the Clutch Switch
125
Checking the Tip Switch and the Emergency off Switch
125
Trouble Shooting in the Electric Starter System
125
Ignition System
126
CDI Unit
127
Checking the Ignition Coil
127
Trouble Shooting in the Ignition System
127
EPC System
128
Dismount / Renew Solenoid Valve for EPC
129
Check of Solenoid Valve for EPC
129
Controller of the EPC System
129
Check of EPC System Microswitch
130
Replacing the EPC System Microswitch
130
Check of Idle Switch / Contact Screws
130
Electrical - Duke-E
131
Checking the Diodes
136
Checking the Side Stand Switch
140
Electrical - SXC '99
141
Electrical - SC '99
142
Checking the Voltage Regulator (Kokusan)
142
Electrical - Duke '99
143
Dynamic Generator Values 400/600 LC4-E / 625 SXC (Kokusan 4K-2)
153
Measuring Conditions
153
Schematic Diagram
154
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 Sensor
162
Fuel System
163
Carburetor - Mikuni BST 40
167
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 Sensor
173
Adjust Idling Speed
174
Adjusting the Throttle Cable
174
Check Float Level
174
Carburetor - Dell'orto PHM 40 SD
175
Disassembling the Carburetor (Dell’orto PHM 40 SD)
176
Assembling the Carburetor (Dell’orto PHM 40 SD)
177
Carburetor - Dell'orto PHM 38 ND
179
Disassembling the Carburetor (Dell’orto PHM 38 ND)
180
Assembling the Carburetor (Dell’orto PHM 38 ND)
182
Carburetor - Dell'orto VHSB 38 QS
184
Disassembling the Carburetor (Dell’orto VHSB 38 QS)
185
Assembling the Carburetor (VHSB 38 QS)
186
Idling Range – a
188
Opening up – B
188
Part-Throttle Range – C
188
Full Throttle Range – D
188
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 Cable
190
Carburetor - Keihin FCR 41
191
Disassembling the Carburetor
192
Checking the Choke Slide
195
Checking the Accelerator Pump
195
Checking the Jet Needle
195
Checking the Float Needle Valve
195
Assembling the Carburetor
196
Adjusting the Position of the Throttle Valve Sensor
199
Checking the Throttle Valve Sensor
200
Dismounting and Installing the Throttle Valve Sensor
200
Adjust Idling
201
Adjusting the Mixture Control Screw
202
Carburetor - Keihin FCR-MX 41
203
Disassembling the Carburetor Keihin FCR - MX 41
204
Checking the Choke Slide and Hot Start Knob
207
Checking the Throttle Valve
207
Assembling the Carburetor Keihin FCR-MX 41
208
CARBURETOR – Adjust Idling (Keihin FCR-MX 41)
213
Checking the Float Level (Float Height)
213
Trouble Shooting
215
Trouble Shooting - SX, SXC, SC, SMC
217
Trouble Shooting - LC4 Competition
219
Trouble Shooting LC4
222
Chassis
225
Dismounting/Mounting the Rocker Arm and Shock Absorber
227
Dismounting/Mounting the Fork Legs
228
Dismounting/Mounting the Swing Arm
228
Replacing the Swing Arm Bearing
229
Replacing the Steering Head Bearing
230
Replacing the Chain, Chain Guide, Pinion and Rear Sprocket
231
Replacing the Front Wheel Bearing
232
Replacing the Rear Wheel Bearing
232
Overhauling the Rocker Arm
233
Replacing the Linkage Bolt Bearing in the Frame
233
Opening the Chain with a Separating/Rivet Tool
234
Riveting the Chain
234
Technical Specifications
235
Engine 400/540 SXC '98
239
Basic Carburetor Setting
239
Chassis 400/540 SXC '98
240
Standard Adjustment - Fork
240
Standard Adjustment - Shock Absorber
240
Engine 400/620 SX, SC '98
241
Chassis 400/620 SX, SC '98
242
Engine 620 LC4 Competition '98
243
Chassis 620 LC4 Comp. '98
244
Engine 400/640 LC4 '98
245
Chassis 400/640 LC4 '98
247
Chassis 640 Adventure R '98
248
Chassis KTM 640 Duke-E '98
249
Engine 400/540 SXC, 620 SX '99
250
Chassis 400/540 SXC, 620 SX '99
251
Engine 400/620 Supercompetition '99
252
Chassis 400/620 Supercompetition '99
253
Engine 620 LC4 Competition '99
254
Chassis 620 LC4 Competition '99
255
Engine 400/640 LC4 '99
256
Chassis 400 LC4 / 640 LC4 / Supermoto '99
257
Engine 640 LC4-E Adventure R '99
258
Chassis 640 Adventure R '99
259
Engine KTM 640 Duke '99
260
Chassis KTM 640 Duke '99
261
400/620 SC, Supermoto 2000
262
Chassis 400/620 SC, Supermoto 2000
263
Engine 400/640 LC4-E, 640 Adventure, Duke 2000
264
Chassis 400/640 LC4-E, 640 LC4-E Supermoto 2000
266
Chassis LC4 Adventure R 640 2000
267
Chassis KTM 640 Duke 2000
268
Chassis 640 Duke 2000 USA, aus
269
Engine 400 SXC USA 2000
270
Chassis 400 SXC USA 2000
271
Engine 620 SC, 620 SC Supermoto 2001
272
Chassis 620 SC, 620 SC Supermoto 2001
273
Engine 400/640 LC4-E, 640 Adventure, Duke 2001
274
Chassis 400/640 LC4-E, 640 LC4-E Supermoto 2001
276
Chassis 640 LC4 Adventure
277
Chassis KTM 640 Duke 2001
278
Chassis 640 Duke 2001 USA, aus
279
Engine 625 SC, 625 SC Supermoto 2002
280
Chassis 625 SC, 625 SC Supermoto 2002
281
Engine 640 LC4 2002
282
Chassis 640 LC4, 640 LC4 Supermoto 2002
283
Chassis 640 Duke II 2002
285
Engine 625 SXC 2003
286
Chassis 625 SXC 2003
287
Engine 640 LC4, 640 LC4 Supermoto 2003
288
Cassis 640 LC4, 640 LC4 Supermoto 2003
289
Chassis 640 LC4 Adventure 2003
290
Chassis 640 Duke II 2003
291
Engine 660 SMC 2003
292
Chassis 660 SMC 2003
293
Engine 625 SXC USA 2004
294
Engine 625 SXC Europe 2004
295
Chassis 625 SXC 2004
296
Engine 640 LC4, 640 LC4 Supermoto 2004
297
Chassis 640 LC4, 640 LC4 Supermoto 2004
298
Chassis 640 LC4 Adventure 2004
299
Chassis 640 Duke II 2004
300
Engine 660 SMC 2004
301
Chassis 660 SMC 2004
302
Engine 625 SXC / SMC 2005
303
Chassis 625 SXC / SMC 2005
304
Engine 640 LC4, Adventure, Duke 2005
305
Chassis 640 LC4 2005
306
Chassis 640 LC4 Adventure 2005
307
Chassis 640 Duke 2005
308
Engine 660 SMC 2005
309
Chassis 660 SMC 2005
310
Tightening Torque - Engine
311
Tightening Torque - Chassis
312
Assembly Clearance, Wear Limit
313
Periodic Maintenance Schedule
315
Vital Checks and Care Procedures to be Conducted by the Owner or the Mechanic
327
Wiring Diagrams
365
400/540 Sxc '98
370
400/620 Sc '98
372
640 Lc4 '99
378
640 Adventure '98/'99
380
640 Duke-E '98
382
620 LC4 Competition '98
384
400 Lc4-E '98 '99 2000
386
640 Lc4-E '2000
388
400/540 Sxc '99
390
400/620 Sc '99-2000
394
400-620 Sc '99
396
640 Adventure 99-2000
398
Duke 2000
400
400/640 Lc4
402
620 Supercomp 2001
404
Mikuni Vergaser 640 Adventure 2001
406
Duke 2001
408
400 Lc4-E 2001
410
640 Lc4-E 2001
412
625 Supercomp 2002
414
640 LC4 Adventure
416
Duke 2002
418
400/640 Lc4-E 2002
420
640 Lc4-E Usa 2002
422
660 Smc 2003
424
625 Sxc 2003-04
426
400/640 Lc4-E 2003-04
428
LC4 Adventure 03-06
430
Adventure 03-06
432
Charging Circuit
433
Ecu
434
Turn Indicator System
435
Light-Brake System
436
Instruments
437
Ground Connection
438
Positive Connection
439
640-Duke 03-06 Wiring Diagram
440
Start System
442
640-Duke 03-06 Charging Circuit
443
640-Duke 03-06 ECU
444
640-Duke 03-06 Turn Indicator System
445
640-Duke 03-06 Light-Brake System
446
640-Duke 03-06 Instruments Tachometer
447
640-Duke 03-06 Ground Connection
448
640-Duke 03-06 Positive Connection
449
660 SMC 2004 Wiring Diagram
450
625 SXC 2005-06 Wiring Diagram
451
Start - Charging System
453
625 Sxc 05-06 Ecu
454
625 SXC 05-06 Turn Indicator System
455
625 SXC 05-06 Light-Brake System
456
625 SXC 05-06 Instruments
457
625 SXC 05-06 Ground Connection
458
625 SXC 05-06 Positive Connection
459
625 SMC 2005-06 Wiring Diagram
460
625 SMC 05-06 Start - Charging System
462
625 Smc 05-06 Ecu
463
625 SMC 05-06 Turn Indicator System
464
625 SMC 05-06 Light-Brake System
465
625 SMC 05-06 Instruments
466
625 SMC 05-06 Ground Connection
467
625 SMC 05-06 Positive Connection
468
LC4-E 03-06 Wiring Diagram
469
LC4-E 03-06 Start System
471
LC4-E 03-06 Charging Circuit
472
Lc4-E 03-06 Ecu
473
LC4-E 03-06 Turn Indicator System
474
LC4-E 03-06 Light-Brake System
475
LC4-E 03-06 Instruments
476
LC4-E 03-06 Ground Connections
477
LC4-E 03-06 Positive Connection
478
LC4-640 SM 2005-06 Wiring Diagram
479
640 SM 05-06 Start System
481
640 SM 05-06 Charging Circuit
482
640 Sm 05-06 Ecu
483
640 SM 05-06 Turn Indicator System
484
640 SM 05-06 Light-Brake System
485
640 SM 05-06 Instruments
486
640 SM 05-06 Ground Connection
487
640 SM 05-06 Positive Connection
488
660 SMC 2005-06 Wiring Diagram
489
660 SMC 2005-06 CDI - Charging Circuit
491
660 SMC 2005-06 Light System - Instruments
492
660 SMC 2005-06 Turn Indicator System
493
660 SMC 2005-06 Positive Connection
494
660 SMC 2005-06 Ground Connection
495
LC4-Rally 2003-06 Wiring Diagram
496
LC4-Rally Ground Connection
498
LC4-Rally Positive Connection
499
LC4-Rally Flasher System
500
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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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