KTM F7403S2 Manuals

Manuals and User Guides for KTM F7403S2. We have 2 KTM F7403S2 manuals available for free PDF download: Repair Manual, Setup Instructions

KTM F7403S2 Repair Manual

KTM F7403S2 Repair Manual (387 pages)

Brand: KTM | Category: Motorcycle | Size: 19.58 MB

Table of Contents

Table of Contents
4
1 Means of Representation 1

9
- Symbols Used
  9
- Formats Used
  9
2 Safety Advice

10
- Repair Manual
  10
- Degrees of Risk and Symbols
  10
- Work Rules
  10
3 Important Notes 3

11
- Manufacturer and Implied Warranty
  11
- Operating and Auxiliary Substances
  11
- Spare Parts, Accessories
  11
- Figures
  11
4 Serial Numbers

12
- Chassis Number
  12
- Type Label
  12
- Engine Number
  12
- Fork Part Number
  12
- Shock Absorber Article Number
  13
5 Motorcycle

14
6 Fork, Triple Clamp

16
7 Handlebar, Controls 7

69
8 Frame

76
9 Shock Absorber, Swingarm

80
10 Exhaust 10

113
- Removing the Manifold
  113
- Installing the Manifold
  114
- Removing the Main Silencer
  115
- Installing the Main Silencer
  116
- Changing the Glass Fiber Yarn Filling in the Main Silencer
  116
11 Air Filter

118
- Air Filter
  118
- Removing the Air Filter Box Cover
  118
- Installing the Air Filter Box Cover
  118
- Removing the Air Filter
  119
- Installing the Air Filter
  119
- Cleaning the Air Filter and Air Filter Box
  120
- Preparing Air Filter Box Cover for Securing
  120
- Sealing the Air Filter Box
  121
12 Fuel Tank, Seat, Trim

122
- Opening the Filler Cap
  122
- Closing the Filler Cap
  122
- Removing the Seat
  123
- Mounting the Seat
  123
- Removing the Fuel Tank
  124
- Installing the Fuel Tank
  125
- Changing the Fuel Screen
  127
- Changing the Fuel Filter
  128
- Changing the Fuel Pump
  131
- Checking the Fuel Pressure
  134
13 Mask, Fender

136
14 Wheels 14

139
- Checking the Tire Air Pressure
  139
- Checking the Tire Condition
  139
- Checking the Wheel Bearing for Play
  140
- Checking the Brake Discs
  141
- Checking the Rim Run-Out
  141
- Checking Spoke Tension
  142
- Front Wheel
  143
- Removing the Front Wheel
  143
- Installing the Front Wheel
  144
- Changing the Front Brake Disc
  144
- Changing Front Wheel Bearing
  145
- Rear Wheel
  146
- Removing the Rear Wheel
  146
- Installing the Rear Wheel
  147
- Changing the Rear Brake Disc
  148
- Changing the Rear Wheel Bearing
  149
- Checking the Chain for Dirt
  151
- Cleaning the Chain
  151
- Checking the Chain Tension
  152
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
  153
- Adjusting the Chain Tension
  155
- Changing the Drivetrain Kit
  156
15 Wiring Harness, Battery 15

159
- Ignition Curve Plug-In Connector
  159
- Changing the Main Fuse
  159
- Changing the Fuses of Individual Power Consumers
  161
- Disconnecting the Negative Cable of the Battery
  162
- Connecting the Negative Cable of the Battery
  163
- Removing the Battery
  163
- Installing the Battery
  164
- Recharging the Battery
  165
- Checking the Charging Voltage
  166
- Checking the Open-Circuit Current
  167
- Checking the Starter Relay
  167
- Diagnostics Connector
  168
16 Brake System 16

169
17 Lighting System, Instruments

184
- Changing the Headlight Bulb
  184
- Changing the Turn Signal Bulb (All EXC Models)
  184
- Checking the Headlight Setting
  185
- Adjusting the Headlight Range
  186
- Changing the Combination Instrument
  186
- Combination Instrument Overview
  187
- Activation and Test
  187
- Setting the Kilometers or Miles
  187
- Adjusting the Combination Instrument Function
  188
- Setting the Clock
  189
- Activating Additional Functions
  189
- Setting the Wheel Circumference
  190
- Viewing the Lap Time
  190
18 Engine

192
- Cleaning the Pressure Sensor Hose
  192
- Removing the Engine
  192
- Installing the Engine
  198
- Engine Disassembly
  205
- Clamping the Engine into the Engine Work Stand
  205
- Removing the Shift Lever
  205
- Removing the Clutch Push Rod
  205
- Draining the Gear Oil
  205
- Removing the Spacer
  206
- Removing the Alternator Cover
  206
- Removing the Kick Starter
  207
- Removing Injection Valves
  207
- Removing the Cylinder Head
  207
- Removing the Cylinder
  208
- Removing the Piston
  210
- Removing the Water Pump Cover
  211
- Removing the Clutch Cover
  211
- Removing the Clutch Discs
  212
- Removing the Clutch Basket
  213
- Removing the Balancer Shaft
  214
- Removing the Kick Starter Shaft
  215
- Removing the Intermediate Kick Starter Gear
  215
- Removing the Shift Shaft
  216
- Removing the Shift Drum Locating Unit
  216
- Removing the Locking Lever
  216
- Removing the Rotor
  216
- Removing the Starter Motor
  217
- Removing the Reed Valve Housing
  218
- Removing the Left Engine Case Section
  219
- Removing the Shift Rails
  219
- Removing the Shift Drum
  219
- Removing the Shift Forks
  220
- Removing the Transmission Shafts
  220
- Removing the Crankshaft
  220
- Working on Individual Parts
  221
- Working on the Right Section of the Engine Case
  221
- Working on the Left Section of the Engine Case
  222
- Removing the Crankshaft Bearing Inner Race
  224
- Installing the Crankshaft Bearing Inner Race
  224
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin
  225
- Checking the Crankshaft Run-Out at the Bearing Pin
  226
- Checking/Measuring the Cylinder
  226
- Cleaning the Pressure Sensor Cylinder Connection
  227
- Removing the Exhaust Control
  227
- Checking the Exhaust Control
  229
- Installing the Exhaust Control
  231
- Cylinder - Nikasil Coating
  234
- Checking/Measuring the Piston
  234
- Checking the Piston Ring End Gap
  235
- Measuring the Piston/Cylinder Mounting Clearance
  235
- Disassemble the Reed Valve Housing
  236
- Checking the Reed Valve Housing, Reed Valve and Intake Flange
  237
- Assemble the Reed Valve Housing
  237
- Working on the Clutch Cover
  239
- Checking the Clutch
  242
- Preassembling Shift Shaft
  243
- Checking the Shift Mechanism
  244
- Disassembling the Main Shaft
  245
- Disassembling the Countershaft
  246
- Checking the Transmission
  246
- Assembling the Main Shaft
  248
- Assembling the Countershaft
  248
- Checking the Kick Starter
  250
- Preassembling the Kick Starter Shaft
  250
- Checking the Electric Starter Drive
  251
- Engine Assembly
  252
- Installing the Crankshaft
  252
- Installing the Transmission Shafts
  253
- Installing the Shift Forks
  253
- Installing the Shift Drum
  254
- Installing the Shift Rails
  254
  - Installing the Left Engine Case Section
    254
  - Installing the Reed Valve Housing
    255
  - Installing the Starter Motor
    256
  - Installing the Rotor
    257
  - Installing the Locking Lever
    257
  - Installing the Shift Drum Locating Unit
    258
  - Installing the Shift Shaft
    258
  - Installing the Intermediate Kick Starter Gear
    258
  - Installing the Kick Starter Shaft
    258
  - Installing the Balancer Shaft
    259
  - Installing the Clutch Basket
    260
  - Installing the Clutch Discs
    261
  - Installing the Clutch Cover
    263
  - Installing the Water Pump Cover
    265
  - Installing the Piston
    266
  - Installing the Cylinder
    267
  - Checking the X-Distance
    269
  - Adjusting the X-Distance
    269
  - Adjusting the Z-Distance
    271
  - Installing the Cylinder Head
    273
  - Installing Injection Valves
    274
  - Installing the Kick Starter
    274
  - Installing the Alternator Cover
    274
  - Installing the Spacer
    275
  - Installing the Gear Oil Drain Plug
    275
  - Installing the Clutch Push Rod
    276
  - Installing the Shift Lever
    276
  - Removing the Engine from the Engine Work Stand
    276
19 Clutch 19

277
20 Water Pump, Cooling System

288
- Cooling System
  288
- Checking the Antifreeze and Coolant Level
  288
- Checking the Coolant Level
  289
- Draining the Coolant
  289
- Refilling with Coolant
  290
21 Exhaust Control 21

293
- Checking/Adjusting the Exhaust Control
  293
22 Lubrication System

296
- Changing the Gear Oil
  296
- Checking the Gear Oil Level
  297
- Adding Gear Oil
  297
- Checking 2-Stroke Oil Level
  298
- Opening 2-Stroke Oil Tank Cap
  299
- Adding 2-Stroke Oil
  299
- Closing 2-Stroke Oil Tank Cap
  299
- Priming the Oil Pump
  300
- Replacing the Oil Pump
  301
23 Ignition System

304
24 Electric Starter 24

311
- Checking the Starter Motor
  311
25 Throttle Valve Body

312
- Adjusting the Idle Speed
  312
- Programming Ambient Pressure
  312
- Cold Start Button
  313
26 Technical Data

314
- Engine
  314
- All 250 Models
  314
- All 300 Models
  314
- Tolerance, Engine Wear Limits
  315
- Engine Tightening Torques
  316
- Capacities
  317
- Gear Oil
  317
- Engine Oil
  317
- Coolant
  317
- Fuel
  318
- Chassis
  318
- Electrical System
  319
- Tires
  319
- Fork
  319
- All Standard EXC/XC-W Models
  319
- All Six Days Models
  320
- Shock Absorber
  320
- Chassis Tightening Torques
  321
27 Cleaning, Care

324
- Cleaning, Care
  324
- Cleaning the Motorcycle
  324
- Checks and Maintenance Steps for Winter Operation
  325
28 Storage

326
- Preparing for Use after Storage
  327
29 Service Schedule

328
- Additional Information
  328
- Required Work
  328
- Recommended Work
  329
30 Wiring Diagram

332
- All EXC Models)
  332
- All EXC Models)
  334
- All EXC Models)
  336
- All EXC Models)
  338
- All EXC Models)
  340
- All EXC Models)
  342
- All EXC Models)
  344
- All EXC Models)
  346
- All XC-W Models)
  348
- All XC-W Models)
  350
- All XC-W Models)
  352
- All XC-W Models)
  354
- All XC-W Models)
  356
- All XC-W Models)
  358
31 Substances

360
32 Auxiliary Substances

362
33 Special Tools

364
34 Standards 34

379
35 Index of Special Terms

380
36 List of Abbreviations 36

381
- Index
  382

Advertisement

KTM F7403S2 Setup Instructions

KTM F7403S2 Setup Instructions (45 pages)

Brand: KTM | Category: Motorcycle | Size: 2.76 MB

Table of Contents

Advertisement

Related Products

KTM Categories

Motorcycle Motorcycle Accessories Offroad Vehicle Engine Bicycle Accessories

More KTM Manuals