Installing The Engine - KTM 400 EXC AUS 2011 Repair Manual

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301ENGINE
102
-
Remove the cable binder and disconnect all connectors of the engine wiring har-
ness in area •.
-
Remove screws •. Take off the clutch slave cylinder and hang it to the side.
Info
I
Do not kink the clutch line.
Do not activate the clutch lever if the clutch slave cylinder has been
removed.
-
Take out the clutch push rod.
-
Slide back cover •. Remove the nut of the electrical connector on the starter
motor and take off the cable.
-
Remove screws •. Lift the engine out of the frame.
Info
I
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.
-
Position the engine in the frame. Mount screws. but do not tighten yet.
Info
I
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.
-
Position the electrical connection on the starter motor. Mount and tighten the nut.
Slide on cover •.
Guideline
Remaining nuts, chassis
M6
15 Nm
(11.1
Ibf ft)
-
Insert the clutch push rod with the small diameter facing the clutch side.
-
Position the clutch slave cylinder. Mount and tighten screws •.
Guideline
I
Screw, clutch slave cylinder
110
Nm (7.4 Ibf
It)
I
-
Attach all connectors of the engine wiring harness in area
e.
-
Position the connectors, wiring harness and clutch line and fix them with cable
binders.
-
Attach the spark plug connector.
-
Attach the engine vent hose. on the valve cover and engine case.
-
Attach the radiator hose with the thermostat. Position hose clamps. and tighten.
-
Attach the radiator hoses. Position hose clamps. and tighten.
301ENGINE
102
-
Remove the cable binder and disconnect all connectors of the engine wiring har-
ness in area •.
-
Remove screws •. Take off the clutch slave cylinder and hang it to the side.
Info
I
Do not kink the clutch line.
Do not activate the clutch lever if the clutch slave cylinder has been
removed.
-
Take out the clutch push rod.
-
Slide back cover •. Remove the nut of the electrical connector on the starter
motor and take off the cable.
-
Remove screws •. Lift the engine out of the frame.
Info
I
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.
-
Position the engine in the frame. Mount screws. but do not tighten yet.
Info
I
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.
-
Position the electrical connection on the starter motor. Mount and tighten the nut.
Slide on cover •.
Guideline
Remaining nuts, chassis
M6
15 Nm
(11.1
Ibf ft)
-
Insert the clutch push rod with the small diameter facing the clutch side.
-
Position the clutch slave cylinder. Mount and tighten screws •.
Guideline
I
Screw, clutch slave cylinder
110
Nm (7.4 Ibf
It)
I
-
Attach all connectors of the engine wiring harness in area
e.
-
Position the connectors, wiring harness and clutch line and fix them with cable
binders.
-
Attach the spark plug connector.
-
Attach the engine vent hose. on the valve cover and engine case.
-
Attach the radiator hose with the thermostat. Position hose clamps. and tighten.
-
Attach the radiator hoses. Position hose clamps. and tighten.

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