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KTM 400-660 LC4 1998-2005, Repair Manual

The KTM 400-660 LC4 Repair Manual provides comprehensive guidance for maintaining and repairing your 1998-2005 model. This essential manual covers all aspects of servicing your bike, from engine overhaul to electrical system troubleshooting. Download it for free from manualshive.com and keep your KTM running smoothly.

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10-7F

Replacing the front wheel bearing

– See Owner's Manual to dismount the front wheel.
– Place the front wheel on 2 blocks of wood with the hub side down.

!

CAUTION

!

D

O NOT REST THE WHEEL ON THE BRAKE DISK

.

– Pull out the distance bushing 

1

, pry the shaft seal ring 

2

out the

hub and remove the lock ring 

3

from the groove with a suitable

tool.

– Pry the shaft seal ring 

4

together with the washer 

5

and the

speedometer driver 

6

.

– Press the bearing spacer sleeve 

7

aside and knock the grooved ball

bearing 

8

out from the opposite side with a driver. 

– Take the bearing spacer sleeve out of the hub and knock out the

second grooved ball bearing 

9

.

– Press a new grooved ball bearing 

8

into the hub with a suitable

tool.

!

CAUTION

!

W

HEN YOU PRESS IN THE BEARING

, 

MAKE SURE TO PRESS THE OUTER RING ONLY

.

I

F YOU PRESS THE INNER RING

, 

THE BALLS OR THE BEARING SURFACES OF THE

BALLS WILL BE DAMAGED

.

– Insert the bearing spacer sleeve in the hub and press in the grooved

ball bearing 

9

, making sure to press on the outer ring only.

– Insert the lock ring 

3

, mount a new shaft seal ring 

2

and press in

the distance bushing 

1

. 

– Insert the speedometer driver 

6

and the washer 

5

in the hub,

mount the shaft seal ring.

Replacing the rear wheel bearing

– See Owner's Manual to dismount the rear wheel.
– Place the rear wheel on 2 blocks of wood with the hub side down.

!

CAUTION

!

D

O NOT REST THE WHEEL ON THE BRAKE DISK

.

– Use a driver to knock out the two distance bushings 

bk

from the

opposite side. 

– Pry the shaft seal ring 

bl

out of the hub and remove the lock ring 

bm

from the groove with a suitable tool.

– Press the bearing spacer sleeve 

bn

aside and knock the grooved ball

bearing 

bo

out from the opposite side with a driver. 

– Take the bearing spacer sleeve out of the hub and knock out the

second grooved ball bearing 

bp

.

– Press a new grooved ball bearing 

bo

into the hub with a suitable

tool.

!

CAUTION

!

W

HEN YOU PRESS IN THE BEARING

, 

MAKE SURE TO PRESS THE OUTER RING ONLY

.

I

F YOU PRESS THE INNER RING

, 

THE BALLS OR THE BEARING SURFACES OF THE

BALLS WILL BE DAMAGED

.

– Insert the lock ring 

bm

and mount a new shaft seal ring 

bl

. Insert the

bearing spacer sleeve in the hub and press in the grooved ball
bearing 

bp

, making sure to press on the outer ring only. 

– Press in the distance bushings 

bk

.

– Use a driver to knock the bushing 

bp

out of the rear sprocket carrier

bq

from the opposite side.

– Remove the washer 

br

and press out the bearing 

bs

.

– Press a new bearing into the hub with a suitable tool.

!

CAUTION

!

W

HEN YOU PRESS IN THE BEARING

, 

MAKE SURE TO PRESS THE OUTER RING ONLY

.

I

F YOU PRESS THE INNER RING

, 

THE BALLS OR THE BEARING SURFACES OF THE

BALLS WILL BE DAMAGED

.

– Slide the washer onto the bushing and press the bushing in the

bearing.

1

2

3

5

4

6

8

7

9

bn

bo

bp

bk

bk

bl

bm

bp

br

bs

4

6

Summary of Contents for 400-660 LC4 1998-2005

Page 1: ...400 660 LC4 REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE R PARATION MANUAL DE REPARACI N Art Nr 3 206 024 E REPAIRMANUAL1998 2005...

Page 2: ......

Page 3: ...REPAIRMANUAL1998 2005 400 660 LC4 KTM Group Partner...

Page 4: ......

Page 5: ...AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 CHASSIS 11 TECHNICAL SPECIFICATIONS 12 PE...

Page 6: ......

Page 7: ...THE BINDER Put the index into the binder Put the front page of the repair manual 210x297 mm into the transparent pocket provided for this purpose on the outside of the binder Put the spine label 170x4...

Page 8: ......

Page 9: ...of Rep Manual LC4 12 2001 Model year 2002 Engine number with first digit 2 3 206 006 E Update of Rep Manual LC4 4 2003 Model year 2003 Engine number with first digit 3 3 206 014 E Update of Rep Manual...

Page 10: ......

Page 11: ...ER MOTORCYCLES UNFIT FOR TRAFFIC NOTE POINTS OUT USEFUL TIPS Use only ORIGINAL KTM SPARE PARTS when replacing parts The KTM high performance engine is only able to meet user expectations if the mainte...

Page 12: ......

Page 13: ...OTE to table Enter the complete item no for the repair manual in column 1 e g 3 210 66 E You will find the number on the cover page or in the left margin on each right page of the manual Enter the cor...

Page 14: ......

Page 15: ...TH FRAME OIL CHANGING THE ENGINE OIL 2 6 CHANGING THE FINE SCREEN FILTER 2 6 CHANGING THE OIL FILTER 2 7 OIL CIRCUIT 2 8 OIL CIRCUIT 660 SMC from model 2004 on 2 9 SECONDARY AIR SYSTEM 2 10 EPC SYSTEM...

Page 16: ......

Page 17: ...pstick Oil capacity up to model 2002 1 40 l Oil capacity from model 2003 on 1 50 l Changing the oil filter Replace the oil filter when changing the engine oil Press the foot brake pedal and place a sc...

Page 18: ...EDIATELY AFTER AN OIL CHANGE KEEP IN MIND THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED WITH ENGINE OIL Allow the engine to run until warm Then turn off the engine and pla...

Page 19: ...filters out even the finest impurities The cleaned engine oil is pumped through the oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase An ad...

Page 20: ...filters out even the finest impurities The cleaned engine oil is pumped through the oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase An ad...

Page 21: ...r when changing the engine oil Loosen the three bolts and remove the cover Undo the spin on filter 3 with the corresponding special tool twist it off manually and let the engine oil out of the front p...

Page 22: ...next to the steering head and use a lubricating syringe 8 584 29 048 000 to fill the front pipe with approx 0 6 l engine oil Add oil until it begins to emerge at bore B Mount the plug using a new seal...

Page 23: ...out even the finest impurities The cleaned engine oil is pumped through the oil line and the clutch cover into the crankshaft to the conrod bearing 7 and drips into the crankcase An additional oil pu...

Page 24: ...ine screen filter 6 which filters out even the finest impurities The cleaned engine oil is pumped through the oil line and the clutch cover into the crankshaft to the conrod bearing 7 and drips into t...

Page 25: ...of the catalytic converter Additionally the secondary air valve prevents the exhaust gases from flowing back into the air filter box 4 When the motorcycle is pushed high underpressure in the intake po...

Page 26: ...ent In an overrun condition extreme vacuum in the intake port the SAS valve 2 will interrupt the air supply to the exhaust port to prevent any exhaust backfire The control valve is regulated by a cont...

Page 27: ...vated during normal operation of the motorcycle It is however activated as soon as the throttle is fully opened at a speed of 45 55 km h while the second or third gear are engaged The EPC control devi...

Page 28: ...00 Knock out tool for bearing seat 6 600 29 018 000 Insert for bearing extractor 7 584 29 086 000 Pressing tool for swing arm bearing 8 584 29 087 000 Sleeve for rocker arm 9 584 29 085 000 Pressing t...

Page 29: ...anual KTM LC4 Art Nr 3 206 014 E SPECIAL TOOLS MOTOR 130 35 65 150 5 70 27 16 6 4 3 26 12 20 7 15 23 2 11 1 39 ThreeBond 1215 Silicone Liquid Gasket Silicone Fl ssige Dichtung 18 17 648 4 5 5 22 48 19...

Page 30: ...et 9 590 29 033 000 Extractor 10 590 29 041 000 Feeler gauge for valve clearance 11 6 899 785 Loctite 243 blue 6 ml 12 584 29 059 000 Loctite 648 red 20 ml 14 590 29 034 000 Wrench for mixture regulat...

Page 31: ...ylinder of the clutch needs to be removed For this purpose remove screws 1 and take off cover 2 together with rubber bellows 3 At the slave cylinder of the clutch remove the bleeder nipple 4 In its pl...

Page 32: ......

Page 33: ...Repair manual KTM LC4 Art Nr 3 206 014 E REMOVING THE ENGINE 3 2 REFITTING THE ENGINE 3 5 CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION CABLE 3 7 REMOVING AND REFITTING ENGINE INDEX 3 1E 3...

Page 34: ......

Page 35: ...tive pole of the battery Undo the 2 hose clamps 1 as well as hose clamp 2 Pull the carburetor backwards out of the intake flange and swing it aside Unhook the 4 springs 3 at the exhaust manifold Undo...

Page 36: ...lutch slave cylinder and pull the clutch slave cylinder off the casing Disconnect the bleeder hose 4 Disconnect the positive cable 5 from the electric starter motor Disconnect all electric plug and so...

Page 37: ...l KTM LC4 Art Nr 3 206 014 E Remove the jet screw 1 Remove the left as well as the right engine retaining bracket 2 Remove bolt 3 as well as the swingarm pivot 4 Then lift the engine out of the frame...

Page 38: ...stening bolts 70 Nm Tighten the jet bolt 4 to 10 Nm Connect all of the electric socket connections to the engine Tighten the banjo bolt 5 to 15 Nm Starting with the 2003 model Tighten the 3 crews 6 on...

Page 39: ...and connect Connect the water hoses 4 and 5 to the water pump Connect the vent hose to the valve cover Connect the vent hose 6 Connect the positive cable 7 to the starter Insert the rear end of the ca...

Page 40: ...0 mm 0 4 in until resistance is felt the exhaust valves begin to open To adjust move back the protective cover 2 loosen the counter nut 3 and correct the adjusting screw 4 accordingly Tighten counter...

Page 41: ...SECTION 4 7 BLOCKING THE CRANKSHAFT 4 8 REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER 4 8 REMOVING CYLINDER HEAD 4 10 REMOVING CYLINDER AND PISTON 4 10 REMOVING ENGINE SPROCKET 4 11 REMOVING CLUTC...

Page 42: ......

Page 43: ...ether with the V seal ring behind Remove bolt 2 together with the washer Then remove the kickstarter Remove spark plug Drain engine oil Remove oil drain plug 3 and magnetic plug 4 and drain oil Removi...

Page 44: ...oil hoses Removing the oil filter Remove all three bolts 3 and take off the oil filter cover together with the O ring or gasket Take the oil filter out of the engine housing Removing the EPC wiring h...

Page 45: ...ut LH thread Remove the disc CAUTION TO AVOID DISTORTION OF THE CRANK WEB NEVER MOUNT THE CRANKSHAFT LOCKING BOLT TO STEADY THE FLYWHEEL Put the protection cover 2 584 29 031 000 onto the crankshaft a...

Page 46: ...TION NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID LOOSENING OF THE MAGNETS Removing the ignition Kokusan 4K 3 Undo the 4 bolts and take off the ignition cover together with the O ring...

Page 47: ...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 an...

Page 48: ...with the seal rings and take off both valve covers together with the gaskets Remove the hexagon nut 5 and take off the retaining bracket of the solenoid valve 6 NOTE A retaining bracket is only used...

Page 49: ...of the crankshaft locking bolt M8 and a copper washer 8x14x3 In this case the special tool 580 30 080 000 must be used Reinsert crankshaft locking bolt by hand If the bolt does not slide smoothly int...

Page 50: ...of the groove Tilt camshaft and remove needle bushing 2 While tilted pull camshaft from camshaft gear and remove together with grooved ball bearing and circlip Take the camshaft gear out of the timin...

Page 51: ...4 and detach cylinder head with gasket Removing cylinder and piston Unscrew the 4 collar nuts at the cylinder base 5 Remove cylinder and cylinder base gasket When working on an engine with a microfilt...

Page 52: ...onnection to the blocked crankshaft is present If the take off shaft cannot be blocked as described above a chain sprocket holder 510 12 012 000 must be applied for the removal of the chain sprocket n...

Page 53: ...sher and the inner clutch hub off the main shaft Try to turn the outer clutch hub in both directions to check the absorbing elements Dead travel in either direction is inadmissible Take the outer clut...

Page 54: ...always be performed on both oil pumps Remove the locking washer 1 Remove stop disc 2 and the oil pump gear 3 Remove the needle roll 4 and stop disc 5 Twist out the 6 bolts 6 and remove the oil pumps f...

Page 55: ...ide Insert timing chain into the clutch compartment of the engine housing and disengage from timing gear Remove the primary gear woodruff key 4 from the crankshaft Withdraw the timing pinion from cran...

Page 56: ...ITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED SINCE THE SEALING SURFACES ARE EASILY DAMAGED Remove housing half and gasket Take the stop disc 1 off the main shaft can stick to the inside of the h...

Page 57: ...care of the shift rolls 6 on the driving pins of the shift forks Pull the shift roller 4 out of the bearing seat Take the shift forks 5 together with the shift rolls 6 out of the engine housing NOTE...

Page 58: ...oving the kickstarter shaft Put kickstarter onto kickstarter shaft and hold in this position Unscrew stop bolt 1 and relieve starter spring tension by releasing the kickstarter Remove kickstarter shaf...

Page 59: ...CYLINDER HEAD TOP SECTION 5 11 CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR 5 12 DISASSEMBLING THE CAMSHAFT AND CHECKING THE COMPONENTS FOR WEAR 5 12 PRE ASSEMBLING THE CAMSHAFT 5 12 AUTOM...

Page 60: ...K 3 5 27 REPLACING THE STATOR KOKUSAN 4K 3 5 27 INDEX 5 2D IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING Read through the following section before commencing work Then determine the assembly sequen...

Page 61: ...have a stop disk instead of the shaft seal ring 5 Do not remove this disk Needle bearing of main shaft 6 Pull old bearing from bearing seat using bearing extracto 151 12 017 000 and insert In order t...

Page 62: ...Pull out the needle bushes of the clutch disengagement with a gear puller 151 12 017 000 and insert from the housing half Oil the needle bushes Press the first needle bush A to stop Press the second n...

Page 63: ...tside press crankshaft roller bearing inwards using a suitable mandrel Press in new roller bearing from inside up to the stop Grooved ball bearing of main shaft 8 Press in new grooved ball bearing fro...

Page 64: ...uld also be changed Heat special tool 584 29 037 040 or 584 29 037 043 on a heating pad up to approx 150 C and slip it on the inner ring immediately Press the special tool together tightly to obtain a...

Page 65: ...mension 65 8 mm Axial play present 0 3 mm The compensating washers should be equally distributed between the two sides of the crankshaft In our example one compensation washer 0 1 mm 0 004 in must be...

Page 66: ...0 mm 0 04 in If the end gap is greater check piston and cylinder for wear If piston and cylinder wear are within the permitted tolerance limits replace the piston ring Measuring piston and cylinder de...

Page 67: ...ed The main advantages of the Nikasil coating are excellent heat dissipation and thus better power output low wear and low weight of the cylinder The worn coating can be regenerated at low cost provid...

Page 68: ...ug gauge can be easily inserted into the valve guide the guide must be replaced in a specialized workshop Valve seats The valve seats must not be pocketed Seat sealing width intake max 1 5 mm 0 059 in...

Page 69: ...k with compensation washers bl into the top section Mount the new O ring 8 the decompression lever spring 9 and the cover disc 7 in such a way that the O ring fits into the recess of the cover disc Mo...

Page 70: ...ed ring bo and the circlip bp Carefully remove the decompression cam bm Keep a watch on the spring 9 Supporting pin bk Check for signs of wear Guide pin bl Check for signs of wear Decompression cam bm...

Page 71: ...ixing up of components Remove screw 3 and take off the oil pump cover 4 Pull the oil pump shaft 5 out of the oil pump housing together with the bearing needle Take the inner rotor 6 and the outer roto...

Page 72: ...s and banjo bolts for damage and clear passage When repairing the engine the microfilter 1 and the oil filter 2 must be replaced Oil lines SC Check oil lines and banjo bolts for damage and clear passa...

Page 73: ...assage When repairing the engine the microfilter 1 and the oil filter 2 must be replaced Oil lines Models with frame oil Check oil lines and banjo bolts for damage and clear passage When repairing the...

Page 74: ...5 640 from modell 2005 660 SMC from modell 2004 Check oil lines and banjo bolts for damage and clear passage When repairing the engine the fine filter 1 and the oil filter 2 must be replaced LOCTITE 2...

Page 75: ...t the markings A and B coincide Clutch cover Balancer shaft bearing bk Use the bearing extractor tool 151 12 017 000 with insert to remove the grooved ball bearing from the bearing seat Insert the new...

Page 76: ...2 5 mm 0 1 in Inner clutch hub 8 Check both the exterior and the interior toothing for signs of wear Needle bearing 9 Check for signs of wear Outer clutch hub bk Check if all rivets bm are tight Absor...

Page 77: ...he shift roller for wear Slide plate 5 Check the contact surfaces for signs of wear Check the return surface B of the slide plate for signs of wear replace in the case of deep grooves Slide guides Che...

Page 78: ...emove the water pump cover 4 together with the gasket Remove circlip 5 from the water pump shaft 6 and pull shaft and water pump wheel 7 out of the grooved ball bearings If grooved ball bearings 8 are...

Page 79: ...smission shafts Mount the idler gears with the bearings on the transmission shafts and check for clearance Check the needle bearings of the idler gears Assembling the main shaft Mount the main shaft i...

Page 80: ...counter shaft Mount counter shaft in vise with collar facing downwards Oil and mount needle cage 1 Slide 2nd gear 2 over needle cage with collar facing downwards Mount stop disc 3 22 7x32 0x1 50 mm wi...

Page 81: ...for signs of wear Heat the flywheel to a temperature of approx 80 C 176 F and remove the 6 bolts CAUTION MAKE SURE THAT THE FLYWHEEL IS NOT HEATED BEYOND 80 C 176 F TO AVOID LOOSENING OF THE MAGNETS...

Page 82: ...NOTE Normally the SAS valve will not require maintenance or cleaning Unscrew the two screws 1 and 2 and remove the covers Loosen the screw 3 and remove the diaphragm plate Check all parts and gaskets...

Page 83: ...r Insert a new stator into the ignition cover Apply Loctite 243 to 3 new bolts and tighten the bolts Insert the cable guide in the opening provided for that purpose in the ignition cover Ignition Koku...

Page 84: ...without however tightening them yet Apply Loctite 243 to the thread of bolt 1 turn the stator clockwise all the way to the stop Fix the cable strand with retaining clips and insert the rubber cable gu...

Page 85: ...t and the bolt 5 to fix it in the ignition cover Ignition Kokusan 4K 3 General information The measurements described below will only reveal severe problems Coil short circuits leading to weak ignitio...

Page 86: ......

Page 87: ...HAFT TIMING MARKS 6 12 MOUNTING THE WATER PUMP 6 13 MOUNTING THE CYLINDER HEAD TOP SECTION 6 14 MOUNTING THE AUTOMATIC TENSIONER 6 14 AUTOMATIC DECOMPRESSION TESTING 6 14 ADJUSTMENT OF VALVE CLEARANCE...

Page 88: ......

Page 89: ...rt stop disc 20 2x35x1 mm 1st gear wheel 3 with collar facing down into the housing and the needle bearing into the idler gear NOTE A roller bearing was installed in the 660 SMC model thus a stop disc...

Page 90: ...ver the locking spring bushing and the locking lever spring onto the third bolt Apply Loctite 243 to the thread of the bolt and mount it Pull locking lever 5 away from the shift roller Put the shift d...

Page 91: ...ift mechanism support If necessary bend the return spring accordingly Pretensioning of the starter spring Fit kickstarter onto kickstarter shaft turn one revolution in starting direction and hold in t...

Page 92: ...ease housing bolts threads and contact surfaces of bolts heads Insert bolts and assemble the housing see sketch for bolt lengths Check all the shafts for smooth operation before and after tightening w...

Page 93: ...models is 2mm thicker CAUTION DO NOT REVERSE DUST LIP OF THE SHAFT SEAL Fit the engine sprocket with the collar facing the housing NOTE For Duke and Supermoto models an additional 2 mm washer is used...

Page 94: ...to the Allen head bolt 6 and mount Mounting the oil pumps Clean the sealing surfaces and install the oil pumps in the engine housing A M6x25 Degrease the threads and use Loctite 243 to secure the bolt...

Page 95: ...RWISE THE GROOVED BALL BEARINGS WOULD DROP OUT OF THE BEARING SEATS AND CAUSE ENGINE DAMAGE AS SOON AS THE ENGINE HEATS UP Mounting the clutch Fit kickstarter intermediate gear 1 onto counter shaft wi...

Page 96: ...bore A in the pressure cap and the pin B of the inner clutch hub coincide Place the springs in the pressure cap and fit the HH srews with spring retainers Secure carefully to 10 Nm in a diagonal patt...

Page 97: ...he dimension Y must be adjusted to make sure the clutch release operates correctly The dimension Y is the distance between the sealing area of the clutch slave cylinder and the pushrod Oil the pushrod...

Page 98: ...the bracket 2 and attach the microfilter NOTE The upper edge of the piston is higher than the upper edge of the cylinder when the cylinder is screwed down Mounting the cylinder head Check both dowels...

Page 99: ...A a point is aligned with the top surface of the cylinder head when the timing chain strand tensioned Tilt engine to one side and place circlip 1 on camshaft gear Slide grooved ball bearing flush ont...

Page 100: ...er 10x28x3 mm and tighten 35 Nm Mounting the water pump Loosen crankshaft locking bolt and turn crankshaft until groove 3 is at a position vertical to the sealing surface for the cylinder head top sec...

Page 101: ...p section with 8 Nm Mounting the automatic tensioner Fit preassembled automatic tensioner with gasket into the cylinder Mount the clamp 4 and two bolts with copper seal rings CAUTION IF THE RATCHETING...

Page 102: ...VE CLEARANCE 625 INTAKE 0 15 mm EXHAUST 0 15 mm VALVE CLEARANCE 640 INTAKE 0 15 mm EXHAUST 0 15 mm VALVE CLEARANCE 660 INTAKE 0 15 mm EXHAUST 0 15 mm Tighten counternuts with 16 Nm Remove the cranksha...

Page 103: ...wheel and crankshaft Thoroughly oil the freewheel and mount the flywheel NOTE Turn the reduction gear for easier mounting of the flywheel Mount disk with the nut Use the holding tool 5 584 29 012 000...

Page 104: ...with Loctite 243 Insert 2 dowels Apply silicone to both sealing surfaces and mount a new gasket Mount ignition cover and tighten all bolts Insert a new O ring 4 into the groove of the starter cover an...

Page 105: ...system the flywheel is provided with an additional mark groove for the 400 LC4 engine The ignition adjustment procedure is exactly the same In the 400 LC4 model the marking B notch must coincide with...

Page 106: ...crankshaft locking bolt is still twisted in Remove the plug at the clutch cover Turn the clutch cover until mark A on the pulse generator and mark B C D or E respectively on the flywheel coincide MODE...

Page 107: ...lutch release lever 3 turn the clutch release shaft clockwise as far as stop and fit the release lever as illustrated Tighten clamp bolt 4 Mounting the electric starter motor Slightly oil the O ring o...

Page 108: ...THE ABOVE CRITERIA Oil capacity up to model 2002 1 40 l Oil capacity from model 2003 on 1 50 l Mounting the kickstarter and the shift lever Put the kickstarter onto the kickstarter shaft then mount bo...

Page 109: ...7 9 CHARGING THE BATTERY 7 9 CHARGING VOLTAGE CHECKING THE VOLTAGE REGULATOR 7 9 CHECKING THE CAPACITOR 7 10 ELECTRIC STARTER SYSTEM 7 11 CHECKING THE START AUXILIARY RELAY 7 12 CHECKING THE AUXILIARY...

Page 110: ......

Page 111: ...TART AUXILIARY RELAY 7 24 CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION 7 24 CHECKING THE DIODES 7 25 CHECKING THE CLUTCH SWITCH 7 25 CHECKING THE EMERGENCY OFF SWITCH 7 25 CHECKING TH...

Page 112: ......

Page 113: ...7 37 CHECKING THE STARTER RELAY 7 38 CHECKING THE ELECTRIC STARTER MOTOR 7 38 TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM 7 38 CHECKING THE IDLE SWITCH 7 38 IGNITION SYSTEM 7 39 CDI UNIT 7 40 CHECK...

Page 114: ......

Page 115: ...the ignition system must be checked for defects Excessive voltage in the circuit The bulbs burn out Connect a voltmeter yellow cable positive brown cable negative to check the voltage Start the engin...

Page 116: ...checking the voltage regulator rectifier Turn off the ignition and disconnect the ground wire from the battery Insert an amperemeter between the ground wire and the negative pole of the battery Setpo...

Page 117: ...OCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION EXPLOSIVE GASES ARE RELEASED DU...

Page 118: ...test lamp must decrease The test lamp must go out after 0 5 2 seconds depending on the lamp capacity If the test lamp does not go out or does not light up at all the capacitor is faulty CAUTION DISCH...

Page 119: ...efore checking the voltage regulator rectifier Turn off the ignition and disconnect the ground wire from the battery Insert an amperemeter between the ground wire and the negative pole of the battery...

Page 120: ...OT REMOVE THE LOCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION EXPLOSIVE GASES...

Page 121: ...f the capacitor marked is made with a test lamp 1 When the power circuit is closed the test lamp must begin to light up As capacitor charging increases the brightness of the test lamp must decrease Th...

Page 122: ...contact of the auxiliary starter relay will enable starting only if at least one of the following conditions is met transmission is set to idle idle switch 6 closed clutch is pulled clutch switch 7 cl...

Page 123: ...ould not light up If it lights up check the diode Switch the transmission to neutral without previously pulling the clutch The auxiliary starting relay should now connect and be tripped as soon as a g...

Page 124: ...ng 0 OK Reading defect NOTE The response of the starter relay is accompanied by a faint clicking sound Checking the electric starter motor Switch off the ignition Disconnect the negative pole of the b...

Page 125: ...e configuration of the connector Then check all lines for ground contact Trouble shooting in the electric starter system When the starter motor fails to turn upon operation of the tip switch perform t...

Page 126: ...ceives its power supply from the battery Therefore it works only with an intact battery When the battery is discharged below the threshold level the voltage can due to the starting process drop below...

Page 127: ...d the free end of the ignition cable approximately 5 mm from ground A strong spark should be visible when the electric starter is now operated If the battery level is low turn off the light and use th...

Page 128: ...aged By opening the solenoid valve bk a dosed amount of fresh air will get to the upper end of the slide membranes of the carburetor This causes the throttle slide to open slowly Thereby the operating...

Page 129: ...w connect a 12V battery to both terminals of the solenoid valve When closing the power circuit a clicking noise must be audible in the solenoid valve the membrane opens If you cannot hear any clicking...

Page 130: ...ug mount tank and seat Check of idle switch contact screws NOTE The contact screw having the cable colors black blue closes the contact when the 2nd gear is engaged The contact screw having the cable...

Page 131: ...y Insert an amperemeter between the ground wire and the negative pole of the battery Setpoint value max 1 mA Check for power consumers should the measured value exceed the indicated maximum value Exam...

Page 132: ...MANUFACTURER WHEN FILLING A NEW BATTERY THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL SUPPLIED WITH THE BATTERY Charging the battery Remove the battery and check the charging...

Page 133: ...the capacitor marked is made with a test lamp 1 When the power circuit is closed the test lamp must begin to light up As capacitor charging increases the brightness of the test lamp must decrease The...

Page 134: ...tion the emergency OFF switch is in the position the transmission is switched to neutral or the clutch is pulled Function of the electric starter system From the battery 1 the battery voltage is trans...

Page 135: ...gear and slowly pull the clutch lever The auxiliary starting relay should respond when the lever is pulled approximately half of the overall distance If this is not the case please check the clutch sw...

Page 136: ...nd check for continuity Connect the ohmmeter in the opposite direction and check if the diode prevents current conduction in the opposite direction Checking the clutch switch Disconnect the clutch swi...

Page 137: ...ole of the battery to connection 2 of the electric starter motor use thick cables The starter must turn as soon as the circuit is closed If this is not the case replace the starter Checking the neutra...

Page 138: ...n pulse is transmitted to the ignition coil 8 i e an ignition spark is generated NOTE The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery T...

Page 139: ...y OFF switch Perform the following tests in the order indicated below The relay must connect in either of the following three cases Put a gear in but do not pull the clutch Slowly swing up the side st...

Page 140: ...e main fuse Check if an ignition spark is produced when the starter is operated Proceed as follows Pull the spark plug connector Disconnect the spark plug connector from the ignition cable Hold the fr...

Page 141: ...ewdriver and remove Connect the negative pole of a 12V battery with the negative terminal of the capacitor The connection between the positive pole of the battery and the positive terminal of the capa...

Page 142: ...apacitor marked is made with a test lamp 3 When the power circuit is closed the test lamp must begin to light up As capacitor charging increases the brightness of the test lamp must decrease The test...

Page 143: ...max 1 mA Check for power consumers should the measured value exceed the indicated maximum value Example defective voltage regulator rectifier leak currents in the socket connectors in the ignition lo...

Page 144: ...E MANUFACTURER WHEN FILLING A NEW BATTERY THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL SUPPLIED WITH THE BATTERY Charging the battery Remove the battery and check the chargin...

Page 145: ...the capacitor marked is made with a test lamp 1 When the power circuit is closed the test lamp must begin to light up As capacitor charging increases the brightness of the test lamp must decrease The...

Page 146: ...tion the emergency OFF switch is in the position the transmission is switched to neutral or the clutch is pulled Function of the electric starter system From the battery 1 the battery voltage is trans...

Page 147: ...gear and slowly pull the clutch lever The auxiliary starting relay should respond when the lever is pulled approximately half of the overall distance If this is not the case please check the clutch sw...

Page 148: ...nd check for continuity Connect the ohmmeter in the opposite direction and check if the diode prevents current conduction in the opposite direction Checking the clutch switch Disconnect the clutch swi...

Page 149: ...2 of the electric starter motor use thick cables The starter must turn as soon as the circuit is closed If this is not the case replace the starter Checking the neutral switch Remove the chain cover...

Page 150: ...n pulse is transmitted to the ignition coil 8 i e an ignition spark is generated NOTE The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery T...

Page 151: ...rgency OFF switch Perform the following tests in the order indicated below The relay must connect in either of the following three cases Put a gear in but do not pull the clutch Slowly swing up the si...

Page 152: ...e fuse under the headlight mask Check if an ignition spark is produced when the starter is operated Proceed as follows Pull the spark plug connector Disconnect the spark plug connector from the igniti...

Page 153: ...entire speed range Multimeter display 14 volts 1 volt NOTE The black measuring lead on the peak voltage adapter should be applied to the ground negative terminal Check the charge current remove main f...

Page 154: ...1 2 5 s g s g 3 6 7 43E...

Page 155: ...of the peak voltage adapter to the red black cable and the black measuring lead to the black yellow cable disconnect connectors 3 and 4 Multimeter display 17 volts 1 volt Same measurement with connec...

Page 156: ...7 8 9 s g s g 3 7 45E...

Page 157: ...and 4 connected this connects the regulatorl rectifier 7 and the CDI unit between black yellow and ground between yellow and ground between red black and ground Multimeter display 12 5 volts 0 5 volt...

Page 158: ...1 2 3 4 5 7 47E...

Page 159: ...e peak voltage adapter to the black red cable and the black measuring lead to the red white cable disconnect connector 3 to disconnect the CDI unit 2 Multimeter display 30 volts 5 volts Same measureme...

Page 160: ...6 9 10 11 7 49E...

Page 161: ...e peak voltage adapter must be applied to the ground Check regulator rectifier output voltage 9 also see circuit diagram on opposite page cable colors yellow red regulator rectifier bk connected capac...

Page 162: ...hecking the speedometer sensor NOTE The measurement must be made with the ignition switched on and the plug and socket connection connected Use a digital multimeter to measure the voltage at the black...

Page 163: ...SB 38 QS 8 21 ASSEMBLING THE CARBURETOR DELL ORTO VHSB 38 QS 8 22 CHECK FLOAT LEVEL DELL ORTO 38 ND 40 SD 8 25 CHECKING AXIAL CLEARANCE OF FLOAT DELL ORTO 38 ND 40 SD 8 25 ADJUST HOT START DEVICE DELL...

Page 164: ......

Page 165: ...43 CHECKING THE JET NEEDLE 8 43 CHECKING THE FLOAT NEEDLE VALVE 8 43 CHECKING THE THROTTLE VALVE 8 43 ASSEMBLING THE CARBURETOR 8 44 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR 8 47 CHECKING T...

Page 166: ......

Page 167: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 3E CARBURETOR MIKUNI BST 40...

Page 168: ...the fuel mixes with the air that flows in through the idling air jet Then the fuel air mixture reaches the idle adjusting screw and the bypass bores through the mixture pipe A certain amount of the f...

Page 169: ...edle jet There it mixes with the air flowing in through the main air jet The result is a fuel air mixture Negative pressure causes this fuel air mixture to flow through the space between the needle je...

Page 170: ...CAUTION TO PREVENT DAMAGING OF THE SLIDE MEMBRANE DO NOT APPLY COMPRESSED AIR TO CLEAN THE CARBURETOR BEFORE REMOVING THE MEMBRANE Remove the two screws 1 and take off the membrane cover Remove the th...

Page 171: ...ew 4 clockwise all the way in Count and write down the number of twists Twist out the mixture adjusting screw and remove it together with the spring the O ring and the washer Use a screwdriver to push...

Page 172: ...Mount the spring the washer and a new O ring on the mixture adjusting screw 3 and twist the mixture adjusting screw all the way in Then twist the mixture adjusting screw back out applying the same nu...

Page 173: ...gital multimeter to measure the voltage between the black and yellow cables at the connector 3 CDI CAUTION SINCE YOU MUST MEASURE WITH THE CONNECTOR ATTACHED MAKE SURE TO CAREFULLY PUSH THE MEASURING...

Page 174: ...r this purpose undo counter nut 3 and turn the adjusting screw until the desired play is achieved Then tighten the counter nut and replace the protective cap After adjusting the throttle cables turn t...

Page 175: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 11E CARBURETOR DELL ORTO PHM 40 SD...

Page 176: ...hrottle slide in a clean piece of cloth and put it onto the air filter box Undo screw bk and take the starting piston out of the carburetor Remove the plug 1 together with the seal ring and take off t...

Page 177: ...ugh all ducts within the carburetor Check all gaskets for damage and exchange them if necessary Assembling the carburetor Dell Orto PHM 40 SD Put the spring the washer and the O ring onto the mixture...

Page 178: ...e with the float Mount the idling mixture pipe and the idling jet 2 Mount the needle jet 3 Position the baffle 4 and fasten it with the main jet holder 5 Mount and tighten the main jet 6 Mount and tig...

Page 179: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 15E CARBURETOR DELL ORTO PHM 38 ND...

Page 180: ...in a clean piece of cloth and put it onto the air filter box Undo screw and take the starting piston out of the carburetor Remove the plug 1 together with the seal ring and take off the float chamber...

Page 181: ...e screw 3 and take off the hose connection together with the fuel filter Twist out the jet holder 4 together with the accelerating jet 5 Remove the 3 screws 6 and take off the entire pump housing 7 to...

Page 182: ...on and mount screw 5 together with the seal ring Put the spring the washer and the O ring onto the mixture adjusting screw 6 and twist the mixture adjusting screw all the way in Twist out the mixture...

Page 183: ...move with the float Mount the idling mixture pipe and the idling jet 4 Mount the needle jet 3 Position the baffle 5 and fasten it with the main jet holder 6 Mount and tighten the main jet 7 Mount and...

Page 184: ...8 20E CARBURETOR DELL ORTO VHSB 38 QS...

Page 185: ...e Wrap the throttle slide in a clean piece of cloth and put it onto the air filter box Undo the screw and pull the entire cold starting device out of the carburetor Remove the three screws 1 and take...

Page 186: ...ing and use compressed air to blow through all ducts within the carburetor Check all gaskets for damage and exchange them if necessary Assembling the carburetor VHSB 38 QS Put the spring the washer an...

Page 187: ...eedle valve 2 Position the float arm 3 and mount pin 4 Mount the idling jet 5 and the starting jet 6 Position the baffle 7 and fasten it with the main jet 8 Put the perforated bushing 9 onto the baffl...

Page 188: ...led b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to be selected Naturally in cases of jet changes you have to start your adjusting work from the...

Page 189: ...functioning of the float there must be an axial play of 0 8 mm 0 03 in If necessary slightly abrade and deburr lateral float guide Adjust hot start device Dell Orto PHM 40SD If the hot start button wa...

Page 190: ...y approx 2 mm from the adjuster piece until feeling a resistance If necessary loosen counter nut and readjust play by turning the adjuster piece Tighten counter nut and slide on protective cover Adjus...

Page 191: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 27E CARBURATOR KEIHIN FCR 41...

Page 192: ...erfect order Dismount the carburetor and remove any coarse dirt Remove the wire clip 1 and pull the ventilation hoses out of the carburetor Disconnect the hose 2 Loosen the 2 screws 3 and dismount all...

Page 193: ...ng and the diaphragm from the pump housing Remove the screw and dismount the float chamber Unhitch the push rod 3 of the accelerator pump and dismount it Take the plastic part 4 off the needle jet Loo...

Page 194: ...he screw and the clip together with the bushing and pull the connection piece 5 out of the carburetor Remove the 2 screws and take the intake trumpet together with the O ring 6 off the carburetor Unsc...

Page 195: ...rittleness Check gaskets for damage Check if the bores 2 are unobstructed Checking the jet needle Check the jet needle for bending and wear Checking the float needle valve Check the sealing surface of...

Page 196: ...ctuate it several times checking whether it can be moved smoothly Besides check whether the choke locks properly Thread the spring the washer and the O ring onto the mixture control screw 6 and screw...

Page 197: ...ush rod 2 of the accelerator pump slides into the bore Place the membrane 3 with the labeling facing upwards and the spring into the pump housing Place the O ring 4 into the groove Secure the sealing...

Page 198: ...d on the right should be identical Then turn the cable disc and check if the throttle valve moves smoothly Mount the jet needle and secure it with the screw 4 Position the slide cover together with it...

Page 199: ...ltiply this value by 0 15 This yields the adjustment value for the throttle valve sensor Example throttle valve sensor resistance bl s 5 k throttle valve sensor resistance ge s 5 k x 0 15 750 50 Conne...

Page 200: ...tle grip slowly the resistance must change evenly throttle valve sensor resistance 0 5 k 1 k while opening the throttle grip Dismounting and installing the throttle valve sensor Disconnect the plug an...

Page 201: ...se Memorize this position and turn mixture control screw slowly counterclockwise until the idling speed will decrease again Adjust the point of the highest idling speed between these two positions If...

Page 202: ...e turns Checking the float level float height For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float ne...

Page 203: ...8 39E Repair manual KTM LC4 Art Nr 3 206 014 E CARBURETOR KEIHIN FCR MX 41...

Page 204: ...tor in perfect order Dismount the carburetor and remove any coarse dirt Loosen both bolts 1 and remove all of the vent hoses from the carburetor Remove both bolts 2 and remove the slide cover and gask...

Page 205: ...pin 1 and remove the float together with the float needle valve Remove the main jet 2 Remove the screw 3 and use pliers to carefully extract the seat of the float needle valve from the carburetor Scr...

Page 206: ...g piece out of the carburetor Remove the 2 screws and take the intake trumpet together with the O ring 4 off the carburetor Unscrew the idle air jet 5 and the main air jet 6 Thoroughly clean all jets...

Page 207: ...posits Checking the accelerator pump Check the membranes for cracking or brittleness Check gaskets for damage Check if the bores 2 are unobstructed Checking the jet needle Check the jet needle for ben...

Page 208: ...ctuate several times checking for smooth operation Also make sure the choke and the hot start knob lock into place Thread the spring the washer and the O ring onto the mixture control screw 7 and scre...

Page 209: ...membrane 5 with the labeling facing upwards and the spring into the pump housing Place the O ring 6 into the groove Secure the sealing ring 7 with some grease in the cover and fasten the cover by mea...

Page 210: ...243 to the screw 1 and tighten Mount the jet needle and fix with the screw 2 Position the slide cover with the gasket and fasten with the 2 screws 3 Fix the vent hoses on the float chamber with the 2...

Page 211: ...le Throttle valve sensor resistance bl s 5k Throttle valve sensor resistance ge s 5 k x 0 15 750 50 Connect the multimeter measuring range x100 to the yellow and the black cable of the throttle valve...

Page 212: ...rip slowly the resistance must change evenly Resistance of throttle valve sensor 0 5 k 1 k while opening the throttle grip Dismounting and installing the throttle valve sensor Disconnect the plug and...

Page 213: ...ontrol screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open b...

Page 214: ......

Page 215: ...Repair manual KTM LC4 Art Nr 3 206 014 E TROUBLE SHOOTING TROUBLE SHOOTING SX SXC SC SMC 9 2 TROUBLE SHOOTING LC4 COMPETITION 9 4 TROUBLE SHOOTING LC4 9 7 INDEX 9 1E 9...

Page 216: ......

Page 217: ...at carburettor lead into a basin and open fuel tap if fuel leaks out clean carburettor if no fuel leaks out check tank ventilation i e clean fuel tap See driving instructions Clean or replace spark p...

Page 218: ...ulator faulty REMEDY Clean and check fuel system as well as carburettor Replace or abrade the float Clean or replace air filter Check if exhaust is damaged replace glas fibre yarn in exhaust silencer...

Page 219: ...will immediately start off when the float chamber is filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel leaks out clean carburetor if no fue...

Page 220: ...stat defective Buckling gearing ventilation hose Engine oil level too high Motor oil too thin viscosity Defective voltage regulator Blown fuse Blown fuse REMEDY Dismount carburetor and check if worn o...

Page 221: ...s defective cable The ignition power consumer has been left on The generator doesn t recharge the battery REMEDY Replace indicator lamp Connect the cable to ground The neutral switch must be replaced...

Page 222: ...ap tank fuel you did not use choke i e the warmstart device Pay attention to starting off information see driving instructions The easily inflammable components of the new fuels evaporate during longe...

Page 223: ...ventilation hose Engine oil level too high Engine oil too thin viscosity REMEDY Disassemble carburetor and clean jets Adjust carburetor Replace spark plug Check ignition system Dismount carburetor an...

Page 224: ...t cable The ignition power consumer hasn t been switched off The battery isn t charged by the generator REMEDY Remove seat and check connections Check voltage regulator Replace fuse below the headligh...

Page 225: ...SWING ARM 10 3 OVERHAULING THE CHASSIS COMPONENTS REPLACING THE SWING ARM SUPPORT 10 4 REPLACING THE STEERING HEAD BEARING 10 5 REPLACING THE CHAIN REAR SPROCKETS AND CHAIN GUIDES 10 6 REPLACING THE F...

Page 226: ......

Page 227: ...TO MAKE IT EASIER TO DISMOUNT Pull the rocker arm 4 out of the swinging fork attachment 7 and remove Remove the brake fluid reservoir for the rear brake cylinder and tilt aside Raise the rear wheel a...

Page 228: ...ng arm See Owner s Manual to remove the rear wheel Remove the chainguard 3 it is attached to the swing arm with 4 screws Remove both screws 4 with the shim plates and the filter box splash protector 5...

Page 229: ...aring sleeves 9 Press both needle bushings bk out of the holes with pressing tool S1 584 29 085 000 smaller diameter using the sleeve S2 584 29 087 000 Turn the pressing tool S1 around and press in th...

Page 230: ...from the steering stem with a suitable extractor and remove the sealing bm Slip a new sealing and a new steering head bearing on the steering stem with a suitable pipe CAUTION WHEN YOU PRESS IN THE B...

Page 231: ...procket carrier in the wheel hub again See Owner s Manual to mount the rear wheel Remove the engine sprocket cover and carefully tilt the clip 5 upwards Lock the engine sprocket with the retaining too...

Page 232: ...e rear wheel on 2 blocks of wood with the hub side down CAUTION DO NOT REST THE WHEEL ON THE BRAKE DISK Use a driver to knock out the two distance bushings bk from the opposite side Pry the shaft seal...

Page 233: ...g sleeves 3 were not replaced the washer can be used again If the bearing sleeve on the swing arm link needs to be replaced make sure the rocker arm is installed without any clearance at the swing arm...

Page 234: ...et 1 over the chain from behind The marks A B must face up Slide pressing pin 3 with the smaller diameter into the spindle of pressing tool 2 and turn spindle back Insert the chain joint shim 7 in the...

Page 235: ...16 TECHNICAL SPECIFICATIONS CHASSIS 400 620 SC 11 17 TECHNICAL SPECIFICATIONS ENGINE 620 LC4 COMPETITION 11 18 TECHNICAL SPECIFICATIONS CHASSIS 620 LC4 COMPETITION 11 19 TECHNICAL SPECIFICATIONS ENGI...

Page 236: ......

Page 237: ...ECIFICATIONS CHASSIS 640 DUKE 11 49 MODELL 2003 TECHNICAL SPECIFICATIONS ENGINE 625 SXC 11 50 TECHNICAL SPECIFICATIONS CHASSIS 625 SXC 11 51 TECHNICAL SPECIFICATIONS ENGINE 640 LC4 ADVENTURE DUKE 11 5...

Page 238: ...ADVENTURE DUKE 11 69 TECHNICAL SPECIFICATIONS CHASSIS 640 LC4 SUPERMOTO 11 70 TECHNICAL SPECIFICATIONS CHASSIS 640 ADVENTURE 11 71 TECHNICAL SPECIFICATIONS CHASSIS 640 DUKE 11 72 TECHNICAL SPECIFICATI...

Page 239: ...heels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless thyristor ignition wit...

Page 240: ...river only 2 0 bar 28 psi Air press road with passenger Fuel tank capacity 9 liter 3 US gallons of that 1 5 liter 0 4 US gallons reserve Final drive ratio 400 14 50 540 15 50 Chain 5 8 x 1 4 O Ring St...

Page 241: ...Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless thyristor ignition with electronic advan...

Page 242: ...eserve Final drive ratio 14 48 14 50 15 40 15 45 15 48 15 50 16 40 16 45 Chain 5 8 x 1 4 Steering angle 62 5 Wheel base 1510 10 mm 59 4 0 4 in Seat high 940 mm 37 in Ground clearance 350 mm 13 8 in De...

Page 243: ...ne oil quantity 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3...

Page 244: ...r 3 2 US gallons of that 2 5 liter 0 7 US gallons res Final drive ratio 16 40 Chain O ring 5 8 x 1 4 Battery maintenance free battery 12V 8Ah Steering angle 62 5 Wheel base 1510 10 mm 59 4 0 4 in Seat...

Page 245: ...st aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication two Eaten oilpumps Engine oil quantity appr 2 1 liters including frame Primary ratio straight...

Page 246: ...5 50 55 400 LC4 25 kW 400 LC4 31 kW BST40 225 080298 142 5 689 X 6 45 6G5 3 rd slide stop 17 mm BST40 225 080298 142 5 689 X 6 45 6G5 3 rd 640 LC4 25 kW 640 LC4 37 kW BASIC CARBURETOR SETTING Type PHM...

Page 247: ...y 2 0 bar 29 psi Air press road with passenger 2 2 bar 31 psi Fuel tank capacity 12 liter 3 2 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 400 LC4 15 45t 640 LC4 16 42t Chain O Ring 5...

Page 248: ...y 2 0 bar 29 psi Air press road with passenger 2 2 bar 31 psi Fuel tank capacity 28 liter 7 4 US gallons 3 8 liter 1 US gallons reserve Final drive ratio 16 40 t Chain O Ring 5 8 x 1 4 Battery mainten...

Page 249: ...liper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H rear 160 60 R 17 69H Air pressure rider only 2 0 bar 29 psi 2...

Page 250: ...ATDC Valve diameter Intake 36 mm Exhaust 30 mm Valve clearance cold Intake 0 20 mm Exhaust 0 20 mm Intake 0 15 mm Exhaust 0 15 mm Crankshaft bearing 2 cylinder roller bearing Conrod bearing needle be...

Page 251: ...psi Air press road driver only 2 0 bar 28 psi Fuel tank capacity 9 liter 3 US gallons of that 1 5 liter 0 4 US gallons reserve Final drive ratio 400 14 50 540 15 50 15 50 Chain 5 8 x 1 4 Steering angl...

Page 252: ...ch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless thyristor ignition with electronic advanced system type KOKUSA...

Page 253: ...oad 1 2 bar 17 psi Air press road driver only 2 0 bar 28 psi Fuel tank capacity 9 liter 2 38 US gallons of that 2 5 liter 0 66 US gallons reserve Final drive ratio 16 48 14 50 16 40 15 50 Chain 5 8 x...

Page 254: ...5 mm Exhaust 0 15 mm Crankshaft bearing 2 cylinder roller bearing Conrod bearing needle bearing Top end bearing bronze bushing Piston cast aluminium alloy Piston rings 1 compression ring 1 taper face...

Page 255: ...i Fuel tank capacity 12 liter 3 2 US gallons of that 2 5 liter 0 7 US gallons res Final drive ratio 16 40 Chain O ring 5 8 x 1 4 Battery maintenance free battery 12V 8Ah Steering angle 62 5 Wheel base...

Page 256: ...ers including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th...

Page 257: ...press road with passenger 2 2 bar 31 psi 2 4 bar 34 psi 2 2 bar 31 psi Fuel tank capacity 12 or 18 liter 3 2 or 4 8 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 400 LC4 15 45 640 LC4...

Page 258: ...gine oil quantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd...

Page 259: ...ss road driver only 2 0 bar 29 psi Air press road with passenger 2 2 bar 31 psi Fuel tank capacity 28 liter 7 4 US gallons 3 8 liter 1 US gallons reserve Final drive ratio 16 40 t Chain O Ring 5 8 x 1...

Page 260: ...er face ring 1 oil scraper ring Engine lubrication 2 Eaton Oilpumps Engine oil 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Tra...

Page 261: ...e Disc brake with carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front...

Page 262: ...clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless thyristor ignition with electronic advanced system type K...

Page 263: ...psi Air press road driver only 1 5 bar 21 psi 2 0 bar 28 psi Tyres rear 140 80 18 Pirelli MT 21 160 60 17 Pirelli MT 60 Air pressure offroad 1 2 bar 17 psi Air press road driver only 2 0 bar 28 psi 2...

Page 264: ...aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication 2 Eaton Oilpumps Engine oil 2 1 liters including frame Primary ratio straight geared spur wheels...

Page 265: ...50 1 50 1 Starting jet 45 50 55 45 50 55 Performance restrictor slide stop 51mm 400 LC4 E 25 kW 400 LC4 E 31 kW 400 LC4 E USA BASIC CARBURETOR SETTING Type BST40 225 BST40 225 BST40 225 Carb setting n...

Page 266: ...liter 4 75 US gallons 2 5 liter 0 66 US gallons reserve Final drive ratio 15 45 16 42 17 42 Chain 5 8 x 1 4 O Ring Lamps head light H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d spee...

Page 267: ...r only 2 0 bar 29 psi Air press road with passenger 2 2 bar 32 psi Fuel tank capacity 28 liter 7 4 US gallons of that 3 5 liter 1 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 O Ring Batt...

Page 268: ...carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H r...

Page 269: ...rake Disc brake with carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres fr...

Page 270: ...ty 1 45 liters 0 38 US gallons Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th...

Page 271: ...e offroad 1 2 bar 17 psi Air press road driver only 2 0 bar 28 psi Fuel tank capacity 9 liter 3 US gallons of that 1 5 liter 0 4 US gallons reserve Final drive ratio 15 50 Chain 5 8 x 1 4 Steering ang...

Page 272: ...81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless thyristor ignition with electr...

Page 273: ...i 2 0 bar 28 psi Tyres rear 140 80 18 160 60 17 Air pressure offroad 1 2 bar 17 psi Air press road driver only 2 0 bar 28 psi 2 2 bar 32 psi Fuel tank capacity 9 liter 2 38 US gallons of that 2 5 lite...

Page 274: ...g 1 oil scraper ring Engine lubrication 2 Eaton Oilpumps Engine oil 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5...

Page 275: ...le valve 50 1 50 1 Starting jet 45 50 55 45 50 55 Performance restrictor slide stop 51mm 400 LC4 E 25 kW 400 LC4 E 31 kW 400 LC4 E USA BASIC CARBURETOR SETTING Type BST40 225 BST40 225 BST40 225 Carb...

Page 276: ...s reserve Final drive ratio 15 45 16 42 17 42 Chain 5 8 x 1 4 O Ring Lamps head light H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d speedometer tachometer light 12V 1 2W socket W2x4...

Page 277: ...river only 2 0 bar 29 psi Air press road with passenger 2 2 bar 32 psi Fuel tank capacity 28 liter 7 4 US gallons of that 3 5 liter 1 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 O Ring...

Page 278: ...carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H r...

Page 279: ...rake Disc brake with carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres fr...

Page 280: ...spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition...

Page 281: ...0 4 US gallons reserve Final drive ratio 16 40 15 50 t 17 38t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V 1 2W socket W2...

Page 282: ...4 Engine oil quantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35...

Page 283: ...Final drive ratio 16 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d instrument lights 12V 1 2W socket W2x4 6d indicator lamps 12V 1 2...

Page 284: ...0 5 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Lampenbest ckung head light H1 12V 55W Sockel P14 5S parking light 12V 2W Sockel Ba9s brake rear light 12V 21 5W Sockel BaY15d fla...

Page 285: ...Disc brake with carbon steel brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 1...

Page 286: ...ission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustmen...

Page 287: ...s 2 5 liter 0 6 US gallons reserve Final drive ratio 16 40 USA 15 50 t Chain X Ring 5 8 x 1 4 Bulps headlight HS1 12V 35 35W socket PX43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V 1 2W...

Page 288: ...n 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN 4K5 Ignition timing adjustment...

Page 289: ...11 liter 2 9 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 16 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d instrum...

Page 290: ...3 5 liter 0 9 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Bulbs head light H1 12V 55W Sockel P14 5S parking light 12V 2W Sockel Ba9s brake rear light 12V 21 5W Sockel BaY15d flas...

Page 291: ...ke with carbon steel floated brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 1...

Page 292: ...rank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston forged aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil...

Page 293: ...ter 0 6 US gallons reserve Final drive ratio 16 38 Chain X Ring 5 8 x 1 4 Bulps headlight HS1 12V 35 35W socket PX43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V 1 2W socket W2x4 6d brak...

Page 294: ...5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to ma...

Page 295: ...oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition t...

Page 296: ...llons 2 5 liter 0 6 US gallons reserve Final drive ratio 16 40 USA 15 50 t Chain X Ring 5 8 x 1 4 Bulps headlight HS1 12V 35 35 W socket P43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V...

Page 297: ...ated Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN 4K5 Ignition t...

Page 298: ...allons 2 5 liter 0 6 US gallons reserve Final drive ratio 16 42t 17 42t Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d instrument lights LED ind...

Page 299: ...s of that 3 5 liter 0 9 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Lampenbest ckung head light H1 12V 55W Sockel P14 5S parking light 12V 2W Sockel Ba9s brake rear light 12V 21...

Page 300: ...rake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H MTR 01 rear 160...

Page 301: ...m Valve clearence cold Intake 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston forged aluminium alloy P...

Page 302: ...eserve Final drive ratio 16 38 Chain X Ring 5 8 x 1 4 Bulps headlight HS1 12V 35 35W socket PX43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V 1 2W socket W2x4 6d brake rear light 12V 21...

Page 303: ...eared spur wheels 31 79 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ign...

Page 304: ...8 x 1 4 X Ring Headlight Parking light Indicator lamps Brake light Rear light Flasher light License plate illmination 12V 35 35 W Sockel P43t 12V 5W Sockel W2 1x9 5d 12V 1 2W Sockel W2x4 6d 12V 21 5W...

Page 305: ...ing 1 oil scraper ring Engine lubrication two Eaton oilpumps Engine oil quantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 31 79 teeth Clutch multi disc clutch in oil b...

Page 306: ...Ring Headlight Parking light Instrument lights Indicator lamps Brake light Rear light Flasher light License plate illmination H4 12V 60 55 W Sockel P43t 12V 5W Sockel W2 1x9 5d LED LED 12V 21 5W Socke...

Page 307: ...liter 6 7 US gallons of that 3 5 liter 0 9 US gallons reserve Final drive ratio 16 42 Chain 5 8 x 1 4 X Ring Lampenbest ckung head light H1 12V 55W base P14 5S parking light 12V 2W base Ba9s brake re...

Page 308: ...floated brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H MTR 0...

Page 309: ...55 US gallons Primary ratio straight geared spur wheels 31 79 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st gear 14 35 2nd gear 15 24 3rd gear 18 21 4th...

Page 310: ...9 2 liter 2 4 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 17 40 Chain 5 8 x 1 4 X Ring Bulps headlight 12V 35 35 W socket P43t parking light 12V 5W socket W2 1x9 5d indicator lamps 1...

Page 311: ...ming chain tensioner to cylinder M6 Loctite 243 8 Nm Timing chain tensioner to cylinder from model 2003 on M6 10 Nm Timing chain guide to cylinder M12x1 25 Loctite 243 8 Nm Hexagon bolt timing chain g...

Page 312: ...swingarm bolt M14x1 5 100 Nm Clamping bolts top triple clamp USD 43 M8 20 Nm Clamping bolts top triple clamp Duke M8 15 Nm Clamping bolts top triple clamp EXTREME M8 15 Nm Clamping bolts top triple c...

Page 313: ...80 mm oil scraper ring max 1 00 mm Valves seat sealing intake max 1 50 mm seat sealing exhaust max 2 00 mm run out of valve heads max 0 05 mm valve guides diameter max 7 05 mm Oil pumps clearance oute...

Page 314: ......

Page 315: ...HEDULE 620 SC 12 10 PERIODIC MAINTENANCE SCHEDULE LC4 E ADVENTURE 12 12 PERIODIC MAINTENANCE SCHEDULE DUKE II 12 14 MODEL 2002 PERIODIC MAINTENANCE SCHEDULE 625 SC 12 16 PERIODIC MAINTENANCE SCHEDULE...

Page 316: ...SCHEDULE 625 SXC SMR 12 38 PERIODIC MAINTENANCE SCHEDULE 640 LC4 640 LC4 SUPERMOTO 12 40 PERIODIC MAINTENANCE SCHEDULE 640 LC4 ADVENTURE 12 42 PERIODIC MAINTENANCE SCHEDULE 640 DUKE 12 44 PERIODIC MA...

Page 317: ...crews at fork legs overpressure Change fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber on forks Check steering head bearing clearance adjust Clean and grease steeri...

Page 318: ...at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance adjust Clean an...

Page 319: ...ks Loosen bleeder screws at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing...

Page 320: ...telescopic fork for leaks Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance adjust Clean an...

Page 321: ...sen breather screws at fork legs overpressure Change fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber on forks Check steering head bearing clearance adjust Clean and...

Page 322: ...sure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance adjust Clean and grease steering hea...

Page 323: ...fork for leaks Loosen bleeder screws at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering...

Page 324: ......

Page 325: ...nction of telescopic fork Check telescopic fork for leaks Loosen breather screws at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Check steer...

Page 326: ...ight turn indicators tell tale lamps speedometer illumination horn emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check adjust smo...

Page 327: ...es in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain flo...

Page 328: ...ors headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for d...

Page 329: ...es in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain flo...

Page 330: ...le lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check adjust...

Page 331: ...s in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain floa...

Page 332: ...t turn indicators tell tale lamps horn Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check adjust smooth operat...

Page 333: ...st sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks D...

Page 334: ...lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Check brake li...

Page 335: ...es in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain flo...

Page 336: ...tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check adj...

Page 337: ...dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leak...

Page 338: ...turn indicators tell tale lamps horn emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check a...

Page 339: ...lar intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box depending on the dirt accumulation Check tire pressure and wear Check coolant level Check fuel...

Page 340: ...ell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Check...

Page 341: ...rvals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box depending on the dirt accumulation Check tire pressure and wear Check coolant level Check fuel lines fo...

Page 342: ...ell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check...

Page 343: ...dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leak...

Page 344: ...smooth operation and kink less arrangement adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and air filter box Check cables for damage and kink less arrangement Ch...

Page 345: ...operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate...

Page 346: ...nd kink less arrangement adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and air filter box Check cables for damage and kink less arrangement Check headlamp adjus...

Page 347: ...eration Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate ch...

Page 348: ...indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws and nuts are tight Check brake fluid level lining th...

Page 349: ...cessary Check chain tension Clean air filter and filter box depending on the dirt accumulation Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all...

Page 350: ...angement adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and air filter box Check cables for damage and kink less arrangement Check headlamp adjustment Check elec...

Page 351: ...ake performance Treat exposed metal components except for the braking and exhaust systems with wax based anti corrosion agents Treat steering lock and light switch with contact spray Check all screws...

Page 352: ...headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for dama...

Page 353: ...dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leak...

Page 354: ...ment Check electrical system for function low high beams stop light turn indicators tell tale lamps horn emergency off switch Make sure all screws and nuts are tight BRAKES Check brake fluid level lin...

Page 355: ...ore each start after every cleaning for cross country use once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper...

Page 356: ...tion low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws and nuts are tig...

Page 357: ...cleaning for cross country use once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and a...

Page 358: ...em for function low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws and n...

Page 359: ...cleaning for cross country use once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and a...

Page 360: ...Check electrical system for function low high beams stop light turn indicators headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make...

Page 361: ...HE OWNER OR THE MECHANIC before each start after every cleaning once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for...

Page 362: ...ustment Check electrical system for function low high beams stop light flashers indicator lamps horn emergency off switch Make sure all screws and nuts are tight BRAKES Check brake fluid level lining...

Page 363: ...rt after every cleaning for cross country use once a year Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation L...

Page 364: ......

Page 365: ...540 SXC 13 23 WIRING DIAGRAM 400 540 SXC Australia 13 25 WIRING DIAGRAM 400 620 SC 13 27 WIRING DIAGRAM 400 620 SC Australia 13 29 WIRING DIAGRAM 640 ADVENTURE R Dell Orto 13 13 WIRING DIAGRAM 640 ADV...

Page 366: ...IAGRAM 660 SMC 13 57 WIRING DIAGRAM 625 SXC 13 59 WIRING DIAGRAM 640 LC4 640 LC4 SUPERMOTO 13 61 WIRING DIAGRAM 640 LC4 ADVENTURE 13 63 WIRING DIAGRAM 640 DUKE 13 73 MODEL 2004 WIRING DIAGRAM 625 SXC...

Page 367: ...70 GROUND CONNECTION 13 71 POSITIVE CONNECTION 13 72 640 DUKE 2003 2005 SWITCHES 13 74 START SYSTEM 13 75 CHARGING SYSTEM 13 76 ECU 13 77 FLASHER HORN COOLING FAN 13 78 LIGHTS 13 79 INSTRUMENTS 13 80...

Page 368: ...3 2005 SWITCHES 13 103 START SYSTEM 13 104 CHARGING SYSTEM 13 105 ECU 13 106 FLASHER HORN COOLING FAN 13 107 LIGHTS 13 108 INSTRUMENTS 13 109 GROUND CONNECTION 13 110 POSITIVE CONNECTION 13 111 640 LC...

Page 369: ...AMS 660 SMC 2005 SWITCHES 13 123 CDI CHARGING SYSTEM 13 124 LIGHTS INSTRUMENTS HORN 13 125 FLASHER 13 126 POSITIVE CONNECTION 13 127 GROUND CONNECTION 13 128 660 RALLY 2003 2005 SWITCHES 13 130 GROUND...

Page 370: ...13 3E...

Page 371: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 4E...

Page 372: ...13 5E...

Page 373: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 6E...

Page 374: ...13 7E...

Page 375: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 8E...

Page 376: ...13 9E...

Page 377: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 10E KTM 400 640 SC 1998...

Page 378: ...13 11E...

Page 379: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 12E...

Page 380: ...13 13E...

Page 381: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 14E...

Page 382: ...13 15E...

Page 383: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 16E...

Page 384: ...13 17E...

Page 385: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 18E...

Page 386: ...13 19E...

Page 387: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 20E...

Page 388: ...13 21E...

Page 389: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 22E...

Page 390: ...13 23E...

Page 391: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 24E...

Page 392: ...13 25E...

Page 393: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 26E...

Page 394: ...13 27E...

Page 395: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 28E...

Page 396: ...13 29E...

Page 397: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 30E...

Page 398: ...13 31E...

Page 399: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 32E...

Page 400: ...13 33E...

Page 401: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 34E...

Page 402: ...13 35E 400 640 LC4 USA...

Page 403: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 36E 400 640 LC4 USA 2000...

Page 404: ...13 37E...

Page 405: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 38E KTM 620 SC 2001...

Page 406: ...13 39E...

Page 407: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 40E...

Page 408: ...13 41E...

Page 409: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 42E...

Page 410: ...13 43E...

Page 411: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 44E...

Page 412: ...13 45E...

Page 413: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 46E KTM 640 LC4 E 2001...

Page 414: ...13 47E 625 SuperComp 2002 SERVICE...

Page 415: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 48E KTM 625 SUPER COMPETITION 2002...

Page 416: ...13 49E SERVICE 640 LC4 ADVENTURE...

Page 417: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 50E KTM 640 LC4 ADVENTURE 2002...

Page 418: ...13 51E SERVICE DUKE 2002...

Page 419: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 52E KTM DUKE 2002...

Page 420: ...bl s s o s r s br r ge r w o ge bl g r br ge bl w r s br bl s ge bl g r bl w s s w KOKUSAN w o g r s s r ge g s bl s s o br br br ge r M br r w r s o ge bl ge s ge bl gr g s ge bl g w ge bl g w br br...

Page 421: ...ectrovanne 42 relaise auxi demarrage 41 contact de temperature 40 contact de embrayage 43 interrutore carburatore 44 valvola elettromagnetica 42 rele avviam ausiliario 41 int temperatura 40 interrutor...

Page 422: ...s o bl s s r s br r ge r w o ge bl g r br ge bl w s s w KOKUSAN w o g r s s r ge g s bl s s o br br br ge r M br r w r s o ge bl ge s ge bl gr g s ge bl g w ge bl g w br br AUS NOT START r s w ge bl o...

Page 423: ...e avviam ausiliario 41 int temperatura 40 interrutore frizione 42 startar auxil relay 41 temperature switch 40 clutch switch 42 Starterhilfsrelais 41 Thermoschalter 40 Kupplungsschalter 38 demarreur e...

Page 424: ...13 57E 660 SMC 2003...

Page 425: ...13 58E Repair manual KTM LC4 Art Nr 3 206 014 E KTM 660 SMC 2003...

Page 426: ...13 59E...

Page 427: ...13 60E Repair manual KTM LC4 Art Nr 3 206 014 E...

Page 428: ...13 61E...

Page 429: ...13 62E Repair manual KTM LC4 Art Nr 3 206 014 E...

Page 430: ...w s r e h s a l f h c t i w s l a r t u e n r o t i c a p a c C_AN 4 3 Z B _ C C_AZ1 4 C_BO 2 t r b r b C_AR 3 pi r o s n e s e r u t a r e p m e t 2 T A _ C headlight 1 2 A B _ C C_AA 20 1 2 F B _ C...

Page 431: ...t r a t s t h g i l g n i s s a p e l b a c u p F F O R N R U T r b u b N R O H i p T R A T S s s e n r a h h w m a e b w o l h g i h h c t i w s r o e l b a c r b l b l b n g h c t i w s l l i k r o...

Page 432: ...e s u f 3th gear 2 1 I A _ C e d o i d y r e t t a b r o t o m r e t r a t s h c t i w s h c t u l c C_BK1 4 m e t s y s t r a t s 5 0 k c a l b n e e r g 2nd gear 5 0 w o l l e y e d o i d neutral sw...

Page 433: ..._AC 6 y r e t t a b m e t s y s t r a t s m e t s y s t h g i l i g i d r o t i c a p a c r e t e m o d e e s l a t 0 3 red white 1 A 0 3 0 1 30 0 1 A A 0 1 A A x o b e s u f 9 3 red 1 r e i f i t c e...

Page 434: ...a e g h t 3 r a e g d n 2 4 1 2 7 8 2 2 3 6 4 1 K B _ C r o t c e l e s e n a t c o 3 2 1 1 1 1 1 1 9 2 1 1 4 1 5 1 6 1 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 1 e g n a r o 5 0 e g n a r o 0 1 1 br...

Page 435: ...e h s a l f E 9 7 e g a p A 0 1 e s u f 9 5 m e t s y s r o t a c i d n i n r u t ignition switch orange 0 5 5 0 e l p r u p 5 0 e u l b w o l l e y 4 Z A _ C 1 e t i h w d e r 0 3 G 5 0 e u l b w o l...

Page 436: ...t i w s t h g i l C_AB 9 F 9 7 e g a p 1 d e r 5 0 e t i h w A 5 1 e s u f C_AH1 2 r a e r yellow brown 1 2 1 L B _ C 1 n w o r b ignition switch h c t i w s e k a r b ignition switch h c t i w s m a...

Page 437: ...C 1 5 6 0 3 0 e r u t n e v d A s t n e m u r t s n i r e t e m o d e e p s l a t i g i d c n u f i t l u m 9 7 2 O B _ C F 9 6 e g a p E 9 5 e g a p 1 D 9 5 e g a p A 9 2 e g a p 4 S P G 4 P B _ C 2...

Page 438: ...b r e h s a l f t n o r f t f e l r o t a l u g e r y r e t t a b r o t o m r e t r a t s M h c t i w s n r o h h c t i w s e r u t a r e p m e t r o s n e s e r u t a r e p m e t r e t e m o d e e p...

Page 439: ...e t t a b r o t o m r e t r a t s y a l e r t r a t s h c t i w s e k a r b t n o r f h c t i w s m a e b w o l h g i h h c t i w s t h g i l n a F yellow 1 yellow blue 1 orange black 0 5 yellow orang...

Page 440: ...0 1 0 1 x o b e s u f C_CI 12 C_CC 12 1 1 A B _ C _ 1 1 F B _ C v 9 B B _ C C_CJ 2 C_CJ 2 2 re 4 M 10 11 re wh 2 6 1 5 1 4 2 7 3 8 ye re driving light lamp 2 4 6 1 2 3 s s e n r a h n i a m 0 0 1 5 7...

Page 441: ...r a t s t h g i l g n i s s a p e l b a c u p F F O R N R U T r b u b N R O H i p T R A T S s s e n r a h h w m a e b w o l h g i h h c t i w s r o e l b a c r b l b l b n g h c t i w s l l i k r o e...

Page 442: ...h c t i w s h c t u l c C_BK1 4 m e t s y s t r a t s 5 0 k c a l b n e e r g 2nd gear 5 0 w o l l e y 2 e d o i d neutral switch 9 B B _ C 1 3 2 T A _ C 7 2 1 1 3 4 2 2 1 2 y a l e r t r a t s 4 3 1...

Page 443: ...b e s u f yellow blue 1 red 4 0 3 A 30 black orange 0 5 4 1 F A _ C 0 3 9 3 red 1 t h g i l e k a r b n r o h r e h s a l f n a f 4 5 6 r e i f i t c e r r o t a l u g e r _ C_BI 2 2 1 2 1 1 C_AU 2 C...

Page 444: ...g d n 2 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 1 e g n a r o 5 0 e g n a r o brown 0 5 brown 0 5 ignition switch N h t 3 d n 2 battery 1 3 9 4 31 1 e t i h w d e r p u k c i p 2 T A _ C 1 3 0 3 h c...

Page 445: ...u f purple 0 5 9 5 m e t s y s r o t a c i d n i n r u t 5 0 n w o r b ignition switch orange 0 5 5 0 e l p r u p 5 0 e u l b w o l l e y C_CC 12 1 e t i h w d e r r e h s a l f t n o r f t h g i r 0...

Page 446: ...2 r a e r p m a l e t a l p e c n e c i l yellow brown 1 brown 0 5 1 n w o r b ignition switch ignition switch h c t i w s m a e b h g i h w o l 2 J C _ C 2 J C _ C C_BB 9 C_BD 12 C_AK1 2 9 5 6 9 1 6...

Page 447: ...t _ s t n e m u r t s n i n 9 7 4 P B _ C r e t e m o d e e p s 2 K A _ C C_CI 12 blue white 0 5 yellow blue 0 5 p m a l t h g i l g n i v i r d 2 1 C C _ C 2 1 I C _ C 1 w o l l e y A 0 1 e s u f 6 2...

Page 448: ...l g n i v i r d r o t o m r e t r a t s r e h s a l f t n o r f t f e l r o t a l u g e r l o r t n o c t h g i l g n i v i r d y r e t t a b C_CC 12 h c t i w s n r o h h c t i w s e r u t a r e p m...

Page 449: ...l f h c t i w s n o i t i n g i C_AN 6 r e t e m o h c a t yellow h c t i w s e k a r b t n o r f h c t i w s m a e b w o l h g i h h c t i w s t h g i l n a F e g n a r o k c a l b p m a l l o r t n...

Page 450: ...asher right rear flasher right front flasher handle bar switch left front flasher rear brake switch U rear light brakelight TPS generator G 3 temperature switch ye bl ye bl br ye re bl ye bl br ye re...

Page 451: ...r e h s a l f t n o r f t f e l 1 C_BG1 3 1 1 1 gr bl 2 1 H A _ C 4 h w r b front C_AJ 3 1 Y A _ C 3 bl or ignition coil 6 1 X B _ C U C E bu wh ye h c t i w s r a b e l d n a h l a n o i t p o n a f...

Page 452: ...w s e l b a c e r e l b a c e y n g u b h c t i w s t h g i l h w r o l o c T H G I L P r b h c t i w s l l i k r o d e h s u p n u s s e n r a h h c t i w s t h g i l e r r b n w o d d e d l o f h w...

Page 453: ...b r o t o m r e t r a t s m e t s y s g n i g r a h c t r a t s 2 U A _ C 1 3 y a l e r t r a t s 1 d e r 1 3 30 n o t t u b t r a t s 6 0 5 0 C X S 5 2 6 8 2 yellow orange 0 5 yellow blue 1 black ora...

Page 454: ...t c e l e s e n a t c o 3 1 1 1 1 1 9 2 1 1 5 1 6 1 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 0 1 1 brown 0 5 brown 0 5 7 ignition switch battery 1 3 8 3 31 1 1 A B _ C 1 A B _ C p u k c i p N 3 E B _...

Page 455: ...1 1 2 2 1 3 2 0 3 3 1 3 D 8 6 e g a p y a l e r r e h s a l f C 8 6 e g a p A 0 1 e s u f 8 4 m e t s y s r o t a c i d n i n r u t ignition switch orange 0 5 5 0 k c a l b 5 0 d e r w o l l e y 1 e t...

Page 456: ...4 3 6 1 2 5 1 1 3 2 8 5 yellow 1 B 8 6 e g a p 1 d e r 2 5 0 e t i h w A 5 1 e s u f C_AH1 2 r a e r ignition switch h c t i w s e k a r b C_BC 6 C_AC 6 ignition switch A 0 1 e s u f 5 0 e u l b w o...

Page 457: ...0 1 e s u f p m a l t h g i l g n i v i r d 4 A D _ C r e t e m o d e e p s l a t i g i d c n u f i t l u m 5 3 4 1 ignition switch 1 d e r 5 0 e g n a r o w o l l e y brown 0 5 A 0 1 e s u f r o t i...

Page 458: ...r a e r t h g i l g n i v i r d n w o r b p m a l l o r t n o c r e h s a l f r o t a l u g e r p m a l l o r t n o c m a e b h g i h y r e t t a b r o t o m r e t r a t s M h c t i w s n r o h r e t...

Page 459: ...a l l o r t n o c e l d i h c t i w s n o i t i n g i y r e t t a b r o t o m r e t r a t s y a l e r t r a t s h c t i w s e k a r b t n o r f h c t i w s t h g i l yellow 1 yellow blue 1 orange bla...

Page 460: ...r e h s a l f r a e r t h g i r bl or ignition coil 6 1 X B _ C U C E bu wh 2 V A _ C ye h c t i w s r a b e l d n a h l a n o i t p o n a f g n i l o o c n g C_AH 2 6 C A _ C 1 r e h s a l f t n o r...

Page 461: ...p e l b a c h c t i w s e l b a c e r e l b a c e y n g u b h c t i w s t h g i l h w r o l o c T H G I L P r b h c t i w s l l i k r o d e h s u p n u s s e n r a h h c t i w s t h g i l e r r b n w...

Page 462: ...t r a t s m e t s y s g n i g r a h c t r a t s red black 1 1 3 y a l e r t r a t s 1 d e r 1 3 30 1 n o t t u b t r a t s 2 3 4 6 0 5 0 C M S 5 2 6 8 2 yellow orange 0 5 yellow blue 1 black orange 0...

Page 463: ...8 2 3 6 r o t c e l e s e n a t c o 3 1 1 1 1 1 9 2 1 1 5 1 6 1 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 0 1 1 brown 0 5 brown 0 5 7 ignition switch battery 1 3 8 3 31 1 1 A B _ C 1 A B _ C p u k c i...

Page 464: ...8 6 e g a p y a l e r r e h s a l f C 8 6 e g a p A 0 1 e s u f 8 4 m e t s y s r o t a c i d n i n r u t ignition switch orange 0 5 5 0 k c a l b 1 e t i h w d e r r e h s a l f t n o r f t h g i r 0...

Page 465: ...W B _ C C_AK1 2 4 3 6 1 2 5 1 1 3 2 8 5 yellow 1 B 8 6 e g a p 1 e t i h w d e r 2 5 0 e t i h w C_AH1 2 r a e r ignition switch h c t i w s e k a r b C_BC 6 C_AC 6 ignition switch A 0 1 e s u f A 0 1...

Page 466: ..._ C A 0 1 e s u f r e t e m o d e e p s l a t i g i d c n u f i t l u m p m a l t h g i l g n i v i r d 5 3 4 1 ignition switch 1 d e r 5 0 e g n a r o w o l l e y A 0 1 e s u f 5 0 n w o r b 5 0 e t...

Page 467: ...i l g n i v i r d n w o r b t h g i r r e h s a l f r o t a l u g e r p m a l l o r t n o c m a e b h g i h r e h s a l f r a e r h c t i w s n r o h M A y a l e r t r a t s r e t e m o d e e p s l a...

Page 468: ...h c t i w s n o i t i n g i r o t o m r e t r a t s h c t i w s e k a r b t n o r f h c t i w s t h g i l yellow 1 yellow blue 1 orange black 0 5 yellow orange 1 1 d e r red black 1 red white 1 r e t...

Page 469: ...a l f t n o r f t h g i r bl wh brake switch 3 E B _ C d n 2 h t 3 N G 2 V A _ C 6 C A _ C h c t i w s m a e b w o l h g i h 2 1 D A _ C 2 1 D B _ C h c t i w s n r o h h c t i w s r e h s a l f r o t...

Page 470: ...n i s s a p e l b a c u p F F O R N R U T r b u b N R O H i p T R A T S s s e n r a h h w m a e b w o l h g i h h c t i w s r o e l b a c r b l b l b n g h c t i w s l l i k r o e r u b u b s s e n r...

Page 471: ...4 e g a p A 9 7 e g a p A 0 1 e s u f 3th gear 2 1 I A _ C e d o i d y r e t t a b r o t o m r e t r a t s h c t i w s h c t u l c C_AZ1 4 m e t s y s t r a t s 5 0 k c a l b n e e r g 2nd gear 5 0 w...

Page 472: ...a b m e t s y s t r a t s m e t s y s t h g i l i g i d r o t i c a p a c r e t e m o d e e s l a t 0 3 red white 1 A 0 3 0 1 30 0 1 A A 0 1 A A x o b e s u f 9 3 red 1 r e i f i t c e r r o t a l u...

Page 473: ..._ C N h c t i w s l a r t u e n r a e g h t 3 r a e g d n 2 4 1 2 7 8 2 2 3 6 4 1 K B _ C r o t c e l e s e n a t c o 3 2 1 1 1 1 1 1 9 2 1 1 4 1 5 1 6 1 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 1 e...

Page 474: ...l f E 9 7 e g a p A 0 1 e s u f 9 5 m e t s y s r o t a c i d n i n r u t ignition switch orange 0 5 5 0 k c a l b 5 0 e u l b w o l l e y 4 Z A _ C 1 e t i h w d e r r e h s a l f t n o r f t h g i...

Page 475: ...C_BD 12 C_AK1 2 9 5 6 9 1 6 2 2 1 3 2 3 9 6 yellow 1 0 1 2 yellow 1 h c t i w s t h g i l C_AB 9 F 9 7 e g a p 1 e t i h w d e r 5 0 e t i h w A 5 1 e s u f C_AH1 2 r a e r yellow brown 1 1 n w o r b...

Page 476: ...5 1 2 3 R A _ C 5 6 0 3 0 E 4 C L s t n e m u r t s n i r e t e m o d e e p s l a t i g i d c n u f i t l u m 9 7 F 9 6 e g a p E 9 5 e g a p 1 D 9 5 e g a p A 9 2 e g a p 4 9 1 r o s n e s d e e p s...

Page 477: ...C L r e h s a l f r a e r t h g i l g n i v i r d n w o r b r e h s a l f t n o r f t f e l r o t a l u g e r y r e t t a b r o t o m r e t r a t s M h c t i w s n r o h h c t i w s e r u t a r e p m...

Page 478: ...h c t i w s n o i t i n g i y r e t t a b r o t o m r e t r a t s y a l e r t r a t s h c t i w s e k a r b t n o r f h c t i w s m a e b w o l h g i h h c t i w s t h g i l n a F yellow 1 yellow blu...

Page 479: ...AH 2 or bl ye br u p r e h s a l f t n o r f t h g i r bl wh brake switch 3 E B _ C d n 2 h t 3 N G 2 V A _ C 6 C A _ C h c t i w s m a e b w o l h g i h 2 1 D A _ C 2 1 D B _ C h c t i w s n r o h h...

Page 480: ...w m a e b w o l h g i h h c t i w s h c t i w s n o i t i n g i l b l b e l b a c l b h c t i w s l l i k r o n w o d d e d l o f h c t i w s d n a t s e d i s s s e n r a h s s e n r a h d e h s u p...

Page 481: ...A 9 7 e g a p A 0 1 e s u f 3th gear 2 1 I A _ C e d o i d y r e t t a b r o t o m r e t r a t s h c t i w s h c t u l c C_AZ1 4 m e t s y s t r a t s 5 0 k c a l b n e e r g 2nd gear 5 0 w o l l e y...

Page 482: ...m e t s y s t h g i l r e t e m o d e e s l a t i g i d 0 3 red white 1 A 0 3 0 1 30 0 1 A A 0 1 A A x o b e s u f 9 3 red 1 r e i f i t c e r r o t a l u g e r C_BC 6 brown 1 0 1 red yellow 1 t i u c...

Page 483: ..._ C N h c t i w s l a r t u e n r a e g h t 3 r a e g d n 2 4 1 2 7 8 2 2 3 6 4 1 K B _ C r o t c e l e s e n a t c o 3 2 1 1 1 1 1 1 9 2 1 1 4 1 5 1 6 1 5 0 k c a l b 5 0 w o l l e y 5 0 e u l b 1 e...

Page 484: ...a l f E 9 7 e g a p A 0 1 e s u f 9 5 m e t s y s r o t a c i d n i n r u t ignition switch orange 0 5 5 0 k c a l b 5 0 e u l b w o l l e y 4 Z A _ C 1 e t i h w d e r r e h s a l f t n o r f t h g i...

Page 485: ...C_BB 9 C_BD 12 C_AK1 2 9 5 6 9 1 6 2 2 1 3 2 3 9 6 yellow 1 0 1 2 yellow 1 h c t i w s t h g i l C_AB 9 F 9 7 e g a p 1 d e r 5 0 e t i h w C_AH1 2 r a e r yellow brown 1 1 n w o r b ignition switch h...

Page 486: ...5 1 2 3 R A _ C 5 6 0 5 0 M S 0 4 6 s t n e m u r t s n i r e t e m o d e e p s l a t i g i d c n u f i t l u m 9 7 F 9 6 e g a p D 9 5 e g a p 1 E 9 5 e g a p A 9 2 e g a p 2 9 1 r o s n e s d e e p...

Page 487: ...r a e r 6 0 5 0 M S 0 4 6 r e h s a l f r a e r t h g i l g n i v i r d n w o r b r e h s a l f t n o r f t f e l r o t a l u g e r y r e t t a b r o t o m r e t r a t s 0 2 M A h c t i w s n r o h h...

Page 488: ...s n o i t i n g i y a l e r t r a t s h c t i w s e k a r b t n o r f h c t i w s m a e b w o l h g i h h c t i w s t h g i l n a F yellow 1 yellow blue 1 orange black 0 5 yellow orange 1 red white 1...

Page 489: ...2 1 3 3 1 2 2 1 1 5 1 6 7 2 l b e y l b e y r e h s a l f r a e r t h g i r C_BG 3 C e r e y r e h s a l f t n o r f t f e l e r C_BK 4 p m a l e t a l p e c n e c i l position light C_AZ 4 C_AJ 3 1...

Page 490: ...e h s u p n u h c t i w s d e h s u p e l b a c l b h c t i w s p o t s r b r o l o c n g u p r b R N R U T e y e y e l b a c e l b a c r b s s e n r a h e y l b e r h c t i w s e k a r b r o F F O s...

Page 491: ...R A _ C 3 M A _ C t i u c r i c g n i g r a h c I D C ye bu C_CR1 1 C_CR 1 n o t t u b p o t s 6 C A _ C h c t i w s m a e b w o l h g i h C r o t a r e n e g l b e y l b e y br bl wh ye bl G 3 br bu...

Page 492: ...y s t h g i l 1 1 2 1 2 1 3 3 2 1 1 2 2 1 5 4 3 6 A 6 2 e g a p C_CX 2 2 h w n g e y h w n g e y e r e r e y e r e y l b r b r b br wh gn gn br bu wh gn bu ye re br bu br C_CW 2 2 C_DB 4 p m a l t h g...

Page 493: ...bl br ye re bl br bl br br ye re e r e y r b r o e r e y 2 V A _ C h c t i w s e r u t a r e p m e t 2 L B _ C 2 D C _ C n a f g n i l o o c 2 1 2 3 H A _ C 2 3 K A _ C G h c t i w s r e h s a l f M p...

Page 494: ...w s e k a r b t n o r f n o i t c e n n o c e v i t i s o p n r o h r e t e m o d e e p s l a t i g i d c n u f i t l u m h c t i w s t h g i l h c t i w s e k a r b r a e r y a l e r r e h s a l f r...

Page 495: ...g i l e k a r b t h g i l r a e r r e h s a l f t n o r f t h g i r r e h s a l f r a e r r b r e h s a l f t n o r f t f e l br br br t h g i l d a e h r o t a l u g e r 6 0 5 0 0 2 C M S 0 6 6 r b...

Page 496: ...a f g n i l o o c l i o bu bl e v i t c e p s r e p r a e r 6 M r o s n e s e r u s s e r p l i o h w l b r b ignition coil h w p h w 2 S A _ C gn wh r b h c t i w s n r o h re wh ye bu 7 re wh A A y...

Page 497: ...b a c e r h c t i w s n r o h r b F F O h c t i w s t h g i l h w r o l o c F F O T H G I L T H G I L P T H G I L P O L I H h c t i w s m a e b w o l h g i h e l b a c n g e y u b N O e l b a c s s e...

Page 498: ...o t o m r e t r a t s k o o b d a o r l i o c n o i t i n g i y r e t t a b h c t i w s n r o h p m a l t h g i l g n i v i r d h c t i w s e r u t a r e p m e t U C E k c o l c m e t s y s r e h s a...

Page 499: ...l b w o l l e y 0 1 0 1 p m a l g n i n r a w l i o S P G 0 1 red white 5 yellow h c t i w s e k a r b t n o r f y a l e r t h g i l g n i v i r d U C E black white A p m a l g n i n r a w e r u t a...

Page 500: ...a R 4 C L m e t s y s r e h s a l f G r e h s a l f t n o r f t f e l r b l b 4 4 y a l e r r e h s a l f u p s t h g i l r e h s a l f r a e r u b e y r e h s a l f t n o r f t h g i r h c t i w s r...

Page 501: ...d positions AA stand for the connector type The 4th position numbers the same type of connector if the connector is used for different applications The 5th and 6th positions 20 specify the number of p...

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