KTM 400-660 LC4 1998-2005 Repair Manual

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REPAIRMANUAL1998-2005

400-660 LC4

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

Table of Contents

Troubleshooting

Summary of Contents for KTM 400-660 LC4 1998-2005

Page 1 REPAIRMANUAL1998-2005 400-660 LC4 REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
Page 3 KTM Group Partner...
Page 5 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING 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 PERIODIC MAINTENANCE SCHEDULE 13 WIRING DIAGRAMS...
Page 7 13-1 13-63 to 13-64 13-63F to 13-134F KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN 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.
Page 9: Table Of Contents
E G E N D E P D A T E 3.205.49-E Repair Manual LC4 6/1998 Basic version 1998 model year (Engine number with first digit “8“) 3.205.73-E Update of Rep.Manual LC4 7/1999 Model year 1999 (Engine number with first digit “9“) 3.205.89-E Update of Rep.Manual LC4 9/2000...
Page 11 „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 maintenance work is performed regularly and professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
Page 13 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –...
Page 15: Table Of Contents
2-1E GENERAL INFORMATION INDEX MODELS WITHOUT FRAME OIL CHANGING THE ENGINE OIL ........2-2 CHANGING THE OIL FILTER .
Page 17: Changing The Engine Oil
2-2E Changing the engine oil (models without frame oil) up to Modell 2001 from Modell 2002 on NOTE: The engine oil change is to be carried out when the engine is still warm. WARNING N ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT ARE VERY HOT DO NOT BURN YOURSELF –...
Page 18: Changing The Microfilter
2-3E Changing the microfilter Replace the microfilter while changing the engine oil. – To do so, remove bolts and take off the microfilter cover – Remove the microfilter, clean its parts and check the O-ring on the microfilter cover for signs of damage. –...
Page 19: Oil Circuit
2-4E Oil circuit The oil pump pumps the engine oil past the by-pass valve through the oil filter . After the oil filter, an oil lead branches off to a jet which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil to the microfilter , which filters out even the finest impurities.
Page 20: Oil Circuit 660 Smc (Model 2003)
2-5E Oil circuit 660 SMC (model 2003) The oil pump pumps the engine oil past the by-pass valve through the oil filter . After the oil filter, an oil lead branches off to a jet which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil to the second jet and the microfilter , which filters out even the finest impurities.
Page 21 2-6E Changing the engine oil (models with frame oil) NOTE: For improved cooling of the engine oil, the front tube of the frame was integrated into the oil circuit.Thus, when you change the oil, you also have to drain the engine oil from the front tube and bleed the oil system.
Page 22: Changing The Oil Filter
2-7E Changing the oil filter Replace the oil filter when changing the engine oil. – Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible.
Page 23 2-8E Oil circuit The oil pump pumps the engine oil past the by-pass valve through the oil filter . After the oil filter, an oil line branches off to a jet which sprays engine oil onto the piston pin bearing and piston head. The second oil line takes the main flow of oil into the front pipe of the frame , where the engine oil is cooled down.
Page 24: Oil Circuit 660 Smc (From Model 2004 On)
2-9E Oil circuit (660 SMC from model 2004 on) The oil pump pumps the engine oil past the by-pass valve through the oil filter . After the oil filter an oil line branches off to the jets 4 which spray engine oil on the piston pin bearing and the piston pins. The second oil line takes the main flow of oil into the front pipe of the frame , where the engine oil is cooled down.
Page 25: Secondary Air System
2-10E Functional characteristics of the secondary air system (SLS) When the exhaust valve is open, the hot exhaust gases flow through the exhaust port at a very high speed. As a consequence of the flow conditions in the exhaust port and due to the influence exerted by the entire exhaust system on the escaping gases, the pressure in the exhaust port drops temporarily (underpressure).
Page 26 2-11E Mode of operation of the secondary air system SAS (starting with the 2004 model) Hot exhaust gases flow through the exhaust port . The flow conditions in the exhaust port and the entire exhaust system's influence on the escaping gas lead to a brief pressure drop in the exhaust port (vacuum). The secondary air valve (SAS) opens during these cyclic vacuum stages, supplying oxygen to the hot exhaust gas through the line...
Page 27: Epc-System
2-12E Electronic Power Control System (EPC) Main components of the EPC system: – Constant-pressure carburetor – Control device – Solenoid valve – 2 contact screws at the engine – Micro-switch (at carburetor) FUNCTIONAL CHARACTERISTICS: The EPC system is not activated 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.
Page 28: Special Tools Chassis
2-13F SPECIALTOOLS – CHASSIS PART NO. DESCRIPTION 151.12.017.000 Bearing extractor 584.29.093.000 Knock-out tool for needle bearing 584.29.089.000 Chassis toolholding 584.29.091.000 Pressing tool for bearing seat / rear wheel bearing 584.29.092.000 Knock-out tool for bearing seat 600.29.018.000 Insert for bearing extractor 584.29.086.000 Pressing tool for swing arm bearing 584.29.087.000...
Page 29: Special Tools Motor
2-14E SPECIAL TOOLS MOTOR...
Page 30 2-15E SPECIAL TOOLS MOTOR FIG. PART NO. DESCRIPTION 560.12.001.000 Universal engine work stand 583.29.003.000 Clutch holder 580.12.005.025 Mounting sleeve for crankshaft seal ring Ø 25 mm 584.29.009.000 Magneto extractor (Kokusan) 580.12.009.000 Magneto extractor (SEM) 510.12.016.000 Protection cover for crankshaft (SEM) 584.29.031.000 Protection cover for crankshaft (Kokusan) 580.12.015.089...
Page 31: Bleeding Of The Hydraulic Clutch
Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer. Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct. If necessary, fill up with biodegradable hydraulic oil SAE 10 (f.ex.
Page 33 3-1E REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ........3-2 REFITTING THE ENGINE .
Page 35 3-2E Removing the engine – Thoroughly clean the entire motorcycle. – When working on a motorcycle with engine guard, remove the latter. – Jack the motorcycle up on a stable supporting device. – Remove the seat, the side covers as well as the tank and the spoilers. –...
Page 36 3-3E – Remove the two bolts and take off the chain guard. – Remove the chain damping plate – Remove the chain joint and take off the chain. From model 2003 on: – Remove the 3 bolts of the clutch slave cylinder and pull the clutch slave cylinder off the casing.
Page 37 3-4E – Remove the jet screw – Remove the left as well as the right engine retaining bracket – Remove bolt as well as the swingarm pivot – Then lift the engine out of the frame.
Page 38 3-5E Mounting the engine – Lift the engine into the frame and position. – Mount the screw and the swing arm pivot but do not tighten yet. – Mount the engine retaining brackets on the left and right. – Tighten the swing arm pivot to 100 Nm.
Page 39 3-6E – Connect the water hose – Attach the clutch cable and the decompression cable. Starting with the 2003 model: – Connect the hose to the SAS valve. – Mount the fan with the screws and connect. – Connect the water hoses to the water pump.
Page 40 3-7E – Tighten the screw – Connect the negative pole to the battery. – Mount the seat, side covers and tank with the spoilers. – When working on a model with an engine guard keep in mind that opening must be located on the right side and face the engine. Checking the adjustment of the hand decompression cable To check, set piston at compression, so that the valves are closed.
Page 41 4-1E DISASSEMBLING THE ENGINE INDEX DRAIN ENGINE OIL .........4-2 REMOVING THE ELECTRIC STARTER MOTOR .
Page 43 4-2E – Fit engine to engine work stand. – Remove bolt together with the washers. Then remove the shift lever together with the V-seal ring behind. – Remove bolt together with the washer. Then remove the kickstarter. – Remove spark plug Drain engine oil up to model 2001 from modell 2002 on...
Page 44 4-3E Removing the clutch release lever and the oil hoses – Undo bolt and remove the clutch release lever. – Remove the two banjo bolts together with the seal rings and remove both oil hoses. Removing the oil filter – Remove all three bolts and take off the oil filter cover together with the O-ring or gasket.
Page 45 4-4E – Undo 6 bolts and remove starter flange incl. gasket. – Insert the holding spanner 584.29.012.000 into the 2 bores of the flywheel. – Hold the flywheel and remove the hexagon nut (LH thread). – Remove the disc. CAUTION O AVOID DISTORTION OF THE CRANK WEB NEVER MOUNT THE CRANKSHAFT LOCKING BOLT TO STEADY THE FLYWHEEL...
Page 46 4-5E Removing the ignition (SEM) – Undo the 4 bolts and remove ignition cover and O-ring. – Use the crankshaft locking bolt 580.30.080.000 to block the crankshaft. – Unscrew collar nut (LH thread) and remove spring disc. – Fit extractor 580.12.009.000 and pull off flywheel. Use protective sleeve 510.12.016.000.
Page 47 4-6E Removing the electric starter drive – Pull the reduction gear off the bearing bolt. – Remove both needle bearings and pull the bearing bolt out of the engine housing. – Remove the freewheel gear and the needle bearing...
Page 48 4-7E Removing the cylinder head top section – Unscrew plug with gasket and remove pressure spring from automatic tensioner. – Undo the 4 hose clamps and remove both hoses ( – Remove all 6 bolts together with the seal rings and take off both valve covers together with the gaskets.
Page 49 4-8F – Pull water pump upward and simultaneously turn crankshaft. NOTE: When groove in the HH bolt is vertical, the water pump can be pulled upward and taken out of the cylinder head without the application of force. Blocking the crankshaft –...
Page 50 4-9E – Using a screwdriver, lever circlip out of the groove. – Tilt camshaft and remove needle bushing – While tilted, pull camshaft from camshaft gear and remove together with grooved ball bearing and circlip. – Take the camshaft gear out of the timing chain as indicated in the illustration.
Page 51 4-10E Removing cylinder head – Unscrew chain guide bolt incl. gasket, bolts and collar nuts – Unscrew the 4 collar bolts and detach cylinder head with gasket. Removing cylinder and piston – Unscrew the 4 collar nuts at the cylinder base –...
Page 52 4-11E – Remove two wire circlips and press piston pin out of piston. – Remove piston. Removing engine sprocket – Remove collar bolt and spring washer. – Remove the sprocket from the counteshaft. – Remove the distance bushing from the countershaft. NOTE: If the gear-box and the clutch of the engine are in good condition, throw it into gear in order to block the take-off shaft (frictional connection to the blocked crankshaft is present).
Page 53 4-12E – Release the lock washer of the inner clutch hub. – Put the clutch holder 583.29.033.000 onto the inner clutch hub and undo the hexagon nut (see illustration). – Remove the clutch holder. – Take the hexagon nut, the lock washer and the inner clutch hub off the main shaft.
Page 54 4-13E – Remove the balancer shaft from the bearing by hand. Removing the oil pumps NOTE: The following procedure must always be performed on both oil pumps. – Remove the locking washer – Remove stop disc and the oil pump gear –...
Page 55 4-14E Removing the timing chain and the timing gear – Remove allan head bolt and remove timing chain guide from the casing. – Unscrew flat-head screw and remove timing chain tensioner. – Unscrew allan head bolt and remove timing chain securing guide. –...
Page 56 4-15E Parting of engine housing – Loosen the crankshaft locking bolt. – Tip ignition side upwards and remove all the housing bolts. – Release engine mount on engine repair stand. – Lift right hand housing half with suitable tools bearing on the bosses provided, or part with a few light plastic mallet blows against the counter shaft.
Page 57 4-16E – Remove the 3 bolts and detach the shift mechanism support – Pull out the shift rails and swing the shift forks aside, taking care of the shift rolls on the driving pins of the shift forks. – Pull the shift roller out of the bearing seat.
Page 58 4-17E Removing the transmission shafts – Pull both transmission shafts out of the bearing seats. – Take the 3rd gear/sliding gear and the 1st gear/idler gear out of the engine housing together with the needle bearing and the stop disc. NOTE: A roller bearing was installed in the 660 SMC model, thus a stop disc is unnecessary.
Page 59 5-1E SERVICING ON INDIVIDUAL COMPONENTS INDEX WORKING ON THE RIGHT HOUSING HALF ..... . .5-3 WORKING ON THE LEFT HOUSING HALF ......5-5 CRANKSHAFT .
Page 60 5-2D INDEX CHECKING THE CLUTCH COMPONENTS FOR WEAR ....5-18 CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR ..5-19 PREASSEMBLY OF SHIFT SHAFT .......5-19 SHIFT MECHANISM SUPPORT .
Page 61 5-3E Working on the right housing half Remove shaft seal rings and heat housing half to approx. 150° C by means of a hot-plate. Roller bearing of crankshaft Proceed as for left housing half. Cylinder roller bearing of counter shaft Remove shaft seal ring.
Page 62 5-4E Needle bushes of the clutch disengagement – 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 to stop. –...
Page 63 5-5E Working on the left half of the housing Remove shaft seal rings and heat housing half to approx. 150° C by means of a hot-plate. Needle bearing of counter shaft Press in new needle bearing from inside until flush. Shaft seal ring of kickstarter shaft Press in new shaft seal ring from outside with sealing lip facing inwards until flush.
Page 64 5-6E Crankshaft If the conrod bearing is replaced, take care to properly position the crankpin. The bores of the crank web and crank pin must coincide. CAUTION F THE CRANK PIN IS PRESSED IN THE WRONG POSITION THE CONROD BEARING IS SUPPLIED INSUFFICIENTLY OR NOT AT ALL WITH ENGINE OIL WHICH RESULTS IN BEARING DAMAGE...
Page 65 5-7F Measuring and adjusting of crankshaft axial clearance – Should the crankshaft, engine housing, or a roller bearing be replaced, the axial clearance of the crankshaft should also be checked. – The housing should be laid inside upwards, then measure the distance from the sealing area to the inner rings of the roller bearings.
Page 66 5-8E Mounting instructions for piston rings – Insert the oil scraper ring in the lower ring groove. Side of ring marked facing piston head. – Mount compression ring (tapered compression piston ring) in middle ring groove. Side of ring marked facing piston head. –...
Page 67 Recoated cylinder If the Nikasil coating of your cylinder is worn but undamaged, you may obtain a recoated cylinder at your KTM dealer (new Nikasil coating on used cylinder). It may be that your spare cylinder shows color changes on the exterior...
Page 68 5-10E Disassembling the cylinder head and checking the components for wear Three-Bond Dichtmasse Three-Bond Gasket – Mount cylinder head in vice using the studs. Do not allow it to rest on sealing surface. – Mark valves and remove using special tool 590.29.019.000. –...
Page 69 5-11E Disassembling the cylinder head top section and checking the components for wear – Simply pull the rocker arm axles out of the cylinder head top section. Then take both rocker arms together with thrust washers out of the cylinder head top section. Undo bolt and remove the following components:...
Page 70 5-12E Checking the components of the timing mechanism for wear Timing chain guide Check for signs of wear. Timing chain tensioner Check for signs of wear. Timing chain Check rollers for smooth operation and signs of wear. Timing gear LOCTITE 243 Check teeth for signs of wear.
Page 71 5-13E Automatic tensioner – Check ratcheting pawl for smooth operation and wear. – Check thrust bolt for wear at teeth. Preassembly of automatic tensioner – Insert thrust bolt into tensioner housing and engage ratcheting pawl into first notch (see illustration). CAUTION F THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE EXCESSIVE TENSION OF THE CHAIN...
Page 72 5-14E Oil lines (SX, SXC) – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the microfilter and the oil filter must be replaced. LOCTITE 243 LOCTITE 243 Oil lines (SC) – Check oil lines and banjo bolts for damage and clear passage. –...
Page 73 5-15E Oil lines (660 SMC model 2003) – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the microfilter and the oil filter must be replaced. LOCTITE 243 LOCTITE 243 Oil lines (Models with frame oil) –...
Page 74 5-16F Oil lines (625/640 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 and the oil filter must be replaced. LOCTITE 243 LOCTITE 243...
Page 75 5-17E Checking the kickstarter components for wear Starter gear Check the bearing for clearance (the starter gear must be in permanent mesh with the outer clutch hub). Intermediate starter gear Check the bearing for clearance. Kick starter shaft Check the toothing for signs of wear. Ratchet gear Check the ascending surface and the toothing for signs of wear.
Page 76 5-18E LOCTITE 243 From model 2003 on Checking the clutch components for wear Thrust bearing – Check for signs of wear. Push rod – Check the face side for signs of wear. Clutch release shaft , sealing cup and needle bearing –...
Page 77 5-19E Checking the shift mechanism components for wear Shift forks Check the fork leaf for signs of wear. Check the shift roller driving pin for signs of wear. Shift rolls Check the shift rolls for hairline cracks and pressure marks. Additionally, make sure that the shift rolls turn easily on the driving pins of the shift forks.
Page 78 5-20E Shift mechanism support – If the grooved ball bearing of the shift roller must be exchanged, press the new grooved ball bearing all the way into the seat. CAUTION O PREVENT DAMAGING OF THE SHIFT MECHANISM SUPPORT DO NOT APPLY EXCESSIVE FORCE WHEN INSERTING THE GROOVED BALL BEARINGS –...
Page 79 5-21E Important note regards working on transmission – Fix the main shaft or countershaft, respectively, in the vise (use special vise jaws to avoid damaging of the shafts) and remove the gear wheels. – Clean and check all parts. Always use new lock washers when performing repair work on the transmission ! Check the tooth profiles of transmission shafts and sliding gears for signs of wear.
Page 80 5-22E Important note regards working on transmission – Fix the main shaft or countershaft, respectively, in the vise (use special vise jaws to avoid damaging of the shafts) and remove the gear wheels. – Clean and check all parts. Always use new lock washers when performing repair work on the transmission ! Check the tooth profiles of transmission shafts and sliding gears for signs of wear.
Page 81 5-23F Removing the intermediate gear – Remove the starter cover. – Pull out the bearing bolt – Remove the intermediate gear and the needle bearing. – Check the parts for signs of wear. – Insert the intermediate gear with the collar downward into the housing for preassembly.
Page 82 5-24E Checking the SAS valve NOTE: Normally the SAS valve will not require maintenance or cleaning. – Unscrew the two screws and remove the covers. – Loosen the screw and remove the diaphragm plate. – Check all parts and gaskets for soiling and damage.
Page 83 5-25E Ignition (Kokusan 4K2) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.
Page 84 5-26E Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.
Page 85 5-27E Ignition (Kokusan 4K-3) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.
Page 87 6-1E ASSEMBLING THE ENGINE INDEX MOUNTING THE KICKSTARTER UNIT ......6-2 MOUNTING TRANSMISSION AND SHIFT MECHANISM ....6-2 ADJUSTMENT OF RETURN SPRING .
Page 89 6-2E – Place left-hand housing half in engine work stand. Mounting the kickstarter unit – Insert stop disc (22.2x35x2 mm), starter gear , needle bearing and stop disc (22.2x30x1.5 mm) into housing. – Insert the pre-assembled kickstarter shaft into the bearing seat, putting it through the starter gear.
Page 90 6-3E – Insert shift roller into the housing with the holder for the locking piece facing up. – Hook the shift forks into the shift roller and mount shift rails The shorter shift rail must be fitted to the main shaft. –...
Page 91 6-4E Adjustment of return spring – Engage second or third gear. – Check free travel of slide plate and check shift pin play. – The free travel of the slide plate is the path this component travels until the shift roller is moved. The return spring pressure will be felt. Proceeding from the basic position, this free travel should be identical for upward and downward movement.
Page 92 6-5E Assembly of engine housing – Make sure both dowels are in place in the left housing half, and put gasket on the sealing surface. Use a little bit of grease to hold the gasket in place. – Grease all shaft seal rings in the left side of the housing. –...
Page 93 6-6F SXC/SMC from 2003 M6x65 M6x55 M6x30 Mounting oil filter – Fit oil filter with rubber gasket onto the connection in the oil filter cover. – Fit a new O-ring into the oil filter cover groove or use new gasket and fix the oil filter cover with the 3 bolts, tighten bolts with 5 Nm.
Page 94 6-7E Mount the timing gear and the timing chain – Insert woodruff key for timing gear into crankshaft and fit timing gear onto crankshaft with high collar towards housing. – Fit timing chain onto timing gear and draw up through chain tunnel. –...
Page 95 6-8F Mounting the balancer shaft and the primary pinion – Fit balancer shaft in the bearing. – Mount woodruff key in crankshaft and place primary pinion on the crankshaft. When doing so, adjust the teeth of the primary pinion and the balancer shaft in such a way that the markings coincide.
Page 96 6-9F Mounting the clutch discs – Thoroughly oil the O-ring and put it onto the inner clutch hub. – Oil the lining disc (internal diameter: 127 mm) and mount it, making sure that the disc encircles the O-ring (see illustration). –...
Page 97: Push Rod
6-10E – Turn the release shaft clockwise until it glides a bit further into the housing. The push rod now sits on the release shaft. – Apply Loctite 243 to the bolt (s). – Fasten the retaining bracket for the clutch release with bolt(s).
Page 98 6-11E – Cut off the section of the housing gasket protruding around the cylinder flange and mount 2 dowels. – Apply sealing compound to the sections near the chain tunnel and mount the cylinder base gasket. NOTE: – To facilitate the installation of the cylinder it is recommended to place a rubber band (see illustration) around the timing chain guide and the timing chain tensioner.
Page 99 6-12E Mounting the camshaft, timing marks – Fit the camshaft gear into the timing chain so that mark (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 on camshaft gear.
Page 100 6-13E – Lubricate the needle bushing with oil and slide it onto the camshaft. – Mount camshaft together with bearing and circlip into cylinder head. – Degrease the threads in the camshaft and the driving bolt and apply Loctite 243. –...
Page 101 6-14E Mounting the cylinder head top section – Clean the sealing area of the cylinder head top section and apply a thin layer of sealing compound (Three Bond) 3090.98. – Fit dowel in the area of the spark plug. – Carefully position cylinder head top section (do not jam with water pump) and mount bolts.
Page 102 6-15F Adjustment of valve clearance – Adjust piston to ignition top dead center (check marks of flywheel) and screw crankshaft locking bolt back in. CAUTION TDC, F THE PISTON IS NOT IN IGNITION VALVES ARE OPENED AND A CORRECT ADJUSTMENT IS NOT POSSIBLE IN THAT CASE CRANKSHAFT MUST BE MOVED A FULL TURN –...
Page 103 6-16E Mounting the electric starter drive – Insert the woodruff key into the crankshaft. – Slide 2 needle bearings onto the bearing pin of the reduction gear. – Slide the needle bearing onto the crankshaft. – Oil the needle bearings. –...
Page 104 6-17E Adjusting the pulse generator – Turn the flywheel until the elevated section of the flywheel coincides with the pulse generator – Use a feeler gauge to measure the distance between the pulse generator and the flywheel. Setpoint value: 0.75 mm (0.03 in) +/- 0.2 mm (0.008 in) –...
Page 105 6-18E Adjustment of ignition point (SEM) NOTE: The ignition point is adjusted after the crankshaft locking bolt has been mounted. – Remove the plug at the ignition cover. – Turn ignition cover so that the mark on the stator and the mark on the flywheel are aligned.
Page 106 6-19F Installing the ignition (Kokusan 4K-3) – Block the crankshaft with the crankshaft locking bolt. – Insert the woodruff key into the crankshaft. – Clean the cone of the flywheel and the crankshaft and mount the flywheel. – Mount the spring washer and the collar nut (LH thread). –...
Page 107 6-20E Mounting the oil hoses – Mount the two oil hoses. – Tighten banjo bolt with 10 Nm and banjo bolt with 15 Nm. Mounting the clutch release lever – To mount the clutch release lever , turn the clutch release shaft clockwise as far as stop and fit the release lever as illustrated.
Page 108 6-21E Pouring in engine oil up to model 2001 from model 2002 on – Mount oil drain plug with seal ring and tighten with 30 Nm. – Mount the magnetic plug and tighten with 20 Nm. NOTE: A third plug was installed in the 660 SMC model. Tightening torque: 20 Nm –...
Page 109 7-1E ELECTRICAL INDEX ELECTRICAL – SUPER COMPETITION ......7-4 CHECKING THE VOLTAGE REGULATOR-RECTIFIER ....7-4 CHECKING THE VOLTAGE REGULATOR .
Page 111 7-2E INDEX DISMOUNT / RENEW SOLENOID VALVE FOR EPC ....7-18 CHECK OF SOLENOID VALVE FOR EPC ......7-18 CONTROLLER OF THE EPC SYSTEM .
Page 113 7-3E INDEX ELECTRICAL – SC ‘99 ........7-31 CHECKING THE VOLTAGE REGULATOR .
Page 115 7-4E ELECTRICAL – SUPER COMPETITION Checking the voltage regulator-rectifier – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage.
Page 116 7-5E ELECTRICAL – LC4 COMPETITION ignition ge-r lock bl ..blue Charging system br ..brown Generator ge ..yellow Regulator-rectifier gr .
Page 117 7-6E Removing the battery – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. CAUTION OLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW BATTERY HE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL...
Page 118 7-7E Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor.
Page 119 7-8E ELECTRICAL – LC4 ignition ge-r lock start relay bl ..blue Charging system br ..brown Generator ge ..yellow Regulator-rectifier gr .
Page 120 7-9E Removing the battery – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. CAUTION OLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW BATTERY HE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL...
Page 121 7-10E Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor.
Page 122 7-11E ge-bl 10 A ge-r to EPC control unit 20 A Electric Starter system Battery Ignition lock NOTE: The electric starter system is equipped with a safety mechanism. Emergency off switch Starting is possible only in the following conditions: Auxiliary relay Tip switch built in emergency off switch ●...
Page 123 7-12E Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay. – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals Reading 0 Ω...
Page 124 7-13E Checking the starter relay – Remove the seat and the right side cover and disconnect the combination connector of the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. – Connect the starter relay to a 12 V battery as indicated in the diagram.
Page 125 7-14E Checking the clutch switch – Disconnect the clutch switch from the cable tree. – Connect the ohmmeter to the 2-pole connector (cable colors: yellow/yellow) of the clutch switch and slowly pull the clutch lever. – The switch must connect when the lever is pulled approximately half of the overall distance.
Page 126 7-15E to EPC-control- unit Battery Ignition system Main fuse (20 A) From the battery , battery voltage is delivered via the main fuse through the activated ignition lock and the activated emergency OFF Ignition lock switch to the CDI unit Emergency-off switch Auxiliary relay During each revolution of the crankshaft, the pulse generator...
Page 127 7-16E CDI unit Check the cables and plug and socket connections of the CDI unit The CDI unit function can only be checked on an ignition test bench. CAUTION EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE UNIT OMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS Checking the ignition coil –...
Page 128 7-17E ge-bl bl-s Battery (12V / 8 Ah) EPC system Main fuse (20 A) Function: Ignition lock From the battery , battery voltage is supplied to the EPC controller Fuse for ignition and start system via the main fuse , the activated ignition lock , and the fuse EPC-control unit Ignition lock...
Page 129 7-18E Dismount / renew solenoid valve for EPC – Remove seat, side covers, and tank with spoilers. – Unplug the solenoid-valve connector. – Disconnect the two hoses, and pull solenoid valve upwards and out of the holder. – Insert new solenoid valve into the holder. –...
Page 130 7-19E Check of EPC system microswitch NOTE: The microswitch is arranged on the left side of the constant- depression carburetor in the area of the throttle valve. If the throttle valve is opened all the way, the microswitch will close the power circuit. –...
Page 131 7-20E ELECTRICAL – DUKE-E ignition ge-r lock start relay tachometer bl ..blue br ..brown ge ..yellow gr ..grey g .
Page 132 7-21E Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90 %). – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. –...
Page 133 7-22E Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor by bridging the two terminals with a screwdriver 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 capacitor (marked +) is made with a test lamp –...
Page 134 7-23E ge-bl ge-r Electric starter system Battery Ignition lock The system is equipped with a safety mechanism. Electric starting is only possible when Emergency off switch Auxiliary relay ● the ignition lock is in the position Tip switch built in emergency off switch ●...
Page 135 7-24E Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay (cable colours red and red-white). – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals Reading 0 Ω...
Page 136 7-25E Checking the diodes NOTE: Diodes conduct current only in the direction indicated by the arrow, preventing the conduction of current in the opposite direction. Two different kinds of diode defects can be distinguished: – The diode conducts no current at all. –...
Page 137 7-26E Checking the starter relay – Remove the seat and the right side cover and disconnect the combination connector of the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. – Connect the starter relay to a 12 V battery as indicated in the diagram.
Page 138 7-27E ge-bl Battery Ignition system Main fuse From the battery the battery voltage is conducted via the main fuse through the ignition lock and the emergency OFF switch Ignition lock which are both ON, to the side stand relay Emergency-off switch The side stand relay conducts the battery voltage to the CDI unit , if Auxiliary relay...
Page 139 7-28E CDI unit Check the cables and plug and socket connections of the CDI unit The CDI unit function can only be checked on an ignition test bench. CAUTION EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE UNIT OMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS Check ignition coil –...
Page 140 7-29E Checking the side stand switch – Disconnect the 2 connectors connecting the side stand switch with the cable tree (below the tank). – Connect an ohmmeter to the side stand cable. – Slowly swing up the side stand. – The switch must be open while the side stand is down. –...
Page 141 7-30E ELECTRICAL – SXC ‘99 Checking the voltage regulator-rectifier – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage.
Page 142 7-31E ELECTRICAL – SC ‘99 Checking the voltage regulator (Kokusan) A defect voltage regulator can cause different kinds of trouble: ● No voltage in the circuit In this case, the voltage regulator must be disconnected at idle speed. The voltage regulator is defect if the power consumers now work properly.
Page 143 7-32E ELECTRICAL – DUKE ‘99 ignition ge-r lock start relay tachometer Charging system bl ..blue br ..brown Generator ge ..yellow Regulator-rectifier gr .
Page 144 7-33E Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90 %). – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. –...
Page 145 7-34E Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor by bridging the two terminals with a screwdriver 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 capacitor (marked +) is made with a test lamp –...
Page 146 7-35E ge-bl ge-r Battery Electric starter system Ignition lock The system is equipped with a safety mechanism. Electric starting is only possible when Emergency off switch Auxiliary relay ● the ignition lock is in the position Tip switch built in emergency off switch ●...
Page 147 7-36E Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay (cable colours red and red-white). – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals Reading 0 Ω...
Page 148 7-37E Checking the diodes NOTE: Diodes conduct current only in the direction indicated by the arrow, preventing the conduction of current in the opposite direction. Two different kinds of diode defects can be distinguished: – The diode conducts no current at all. –...
Page 149 7-38E Checking the starter relay – Remove the seat and disconnect the combination connector the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. – Connect the starter relay to a 12 V battery as indicated in the diagram.
Page 150 7-39E ge-bl Battery Ignition system Main fuse From the battery the battery voltage is conducted via the main fuse through the ignition lock and the emergency OFF switch Ignition lock which are both ON, to the side stand relay Emergency-off switch The side stand relay conducts the battery voltage to the CDI unit , if Auxiliary relay...
Page 151 7-40E CDI unit Check the cables and plug and socket connections of the CDI unit The CDI unit function can only be checked on an ignition test bench. CAUTION EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE UNIT OMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS Check ignition coil –...
Page 152 7-41E Checking the side stand switch – Disconnect the 2 connectors connecting the side stand switch with the cable tree (below the tank). – Connect an ohmmeter to the side stand cable. – Slowly swing up the side stand. – The switch must be open while the side stand is down. –...
Page 153 7-42E DYNAMIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – remove seat (also side trim and left side cover for Racing model) – all connectors and the ground connection in a non-corroding condition, connectors tightly connected –...
Page 154 7-43E s–g...
Page 155 7-44E STATIC IGNITION VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – cold engine – seat, side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded, ignition switch to position 1 (without light) –...
Page 156 7-45E s–g...
Page 157 7-46E STATIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – cold engine – seat, side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded, ignition switch to position 1 (without light) –...
Page 158 7-47E...
Page 159 7-48E STATIC IGNITION VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C) Measuring conditions: – cold engine – seat, right side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off –...
Page 160 7-49E...
Page 161 7-50E STATIC GENERATOR VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C) Measuring conditions: – cold engine – seat, right side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off –...
Page 162 7-51E Checking the speedometer sensor and the speedometer (Adventure – from the 2002 model) Checking the speedometer: – Disconnect the connector from the speedometer. NOTE: The connector is located under the cockpit covering. – Switch on the ignition. – Briefly connect pins (cable colors black/brown and black/orange) with a cable several times while you observe the speed reading.
Page 163: Fuel System
8-1E FUEL SYSTEM INDEX MIKUNI BST 40 PART-LOAD SYSTEM ........8-4 FULL-LOAD SYSTEM .
Page 165 8-2E INDEX KEIHIN FCR-MX 41 DISASSEMBLING THE CARBURETOR ......8-40 CHECKING THE CHOKE SLIDE ....... .8-43 CHECKING THE ACCELERATOR PUMP .
Page 167 8-3E CARBURETOR - MIKUNI BST 40...
Page 168 8-4E FUEL AIR MIXTURE FUEL Part-load system (Mikuni BST 40) The part-load system supplies the engine with fuel while the throttle slide is closed or only slightly opened. From the float chamber the fuel enters the mixture pipe through the idling jet. There the fuel mixes with the air that flows in through the idling air jet.
Page 169 8-5E FUEL AIR MIXTURE FUEL Full-load system (Mikuni BST 40) When the throttle valve is opened the engine speed increases and the negative pressure in the venturi pipe grows. The same negative pressure is transferred to the upper side of the slide membrane and pulls the throttle slide upwards.
Page 170 8-6E Disassembling the carburetor (Mikuni BST-40) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. CAUTION O PREVENT DAMAGING OF THE SLIDE MEMBRANE DO NOT APPLY COMPRESSED AIR TO CLEAN THE CARBURETOR BEFORE REMOVING THE MEMBRANE –...
Page 171 8-7E – Take the entire float unit out of the carburetor. – Then remove the main jet together with the distance bushing. – Remove the idling jet – Twist the mixture adjusting screw 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.
Page 172 8-8E Assembling the carburetor (Mikuni BST 40) – Put the needle jet into the carburetor, making sure that the flat portion is located next to the jet needle. – Put the distance bushing onto the needle jet and mount the main –...
Page 173 8-9E – Mount the throttle slide, making sure that the membrane of the throttle slide rests properly against the round wall of the carburetor housing. – Insert the spring into the throttle slide. – Put the throttle stop into the membrane cover. NOTE: The throttle stop shown in the picture is fitted in a restricted version.
Page 174 8-10E Adjust idling speed NOTE: Warm up the engine before adjusting the idle speed. Use the adjusting screw to adjust the basic position of the throttle valve and, thus, the idle speed. Turning in clockwise direction will increase the idling speed, turning in counterclockwise direction will reduce the idling speed.
Page 175 8-11E CARBURETOR – DELL’ORTO PHM 40 SD...
Page 176 8-12E Disassembling the carburetor (Dell’Orto PHM 40 SD) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Remove the two screws and pull the carburetor cover out of the carburetor together with the throttle slide.
Page 177 8-13E – Twist the mixture adjusting screw clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring. – Twist the adjusting screw clockwise all the way in, counting and writing down the number of twists.
Page 178 8-14E – Position the float and mount the pin . When mounting the float make sure that the needle valve properly engages with the float. Check by moving the float upwards: the needle valve must move with the float. – Mount the idling mixture pipe and the idling jet –...
Page 179 8-15E CARBURETOR – DELL’ORTO PHM 38 ND...
Page 180 8-16E Disassembling the carburetor (Dell’Orto PHM 38 ND) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Remove the two screws and pull the carburetor cover out of the carburetor together with the throttle slide.
Page 181 8-17E – Twist the mixture adjusting screw clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring. – Twist the adjusting screw clockwise all the way in, counting and writing down the number of twists.
Page 182 8-18E Assembling the carburetor (Dell’Orto PHM 38 ND) – Position the pump housing together with the gasket and fasten them with the 3 screws. Make sure that the membrane is properly positioned in the pump housing. – Put the seal ring onto the jet holder and mount the jet holder together with the accelerating jet .
Page 183 8-19E – Position the float and mount the pin . When mounting the float make sure that the needle valve properly engages with the float. Check by moving the float upwards: the needle valve must move with the float. – Mount the idling mixture pipe and the idling jet –...
Page 184 8-20E CARBURETOR – DELL’ORTO VHSB 38 QS...
Page 185 8-21E Disassembling the carburetor (Dell’Orto VHSB 38 QS) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Open the cap and pull the carburetor cover out of the carburetor together with the throttle slide.
Page 186 8-22E – Twist out the needle jet – Twist the mixture adjusting screw clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring.
Page 187 8-23E – Mount the needle jet – Insert the seal ring into the carburetor bore and mount the needle valve – Position the float arm and mount pin – Mount the idling jet and the starting jet – Position the baffle and fasten it with the main jet –...
Page 188 8-24E main jet jet needle jet needle idling jet throttle valve mixture regulating screw idle adjusting screw Idling range – A Operation with closed throttle valve. This range is influenced by the position of the air control screw and the idle adjusting screw .
Page 189 8-25E Mixture too rich: Too much fuel in proportion to air Mixture too lean: Not enough fuel in proportion to air Check float level (Dell’Orto PHM 38ND / 40SD) Stand the carburettor diagonally at about 60° so that the spring in the float needle valve is not pressed together.
Page 190 8-26E Adjusting the throttle cable There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. 3-5 mm To check this, move back the protective cover on the throttle grip. You must be able to lift the outer covering of the cable 3-5 mm from the adjusting screw , until resistance is felt.
Page 191 8-27E CARBURATOR - KEIHIN FCR 41...
Page 192 8-28E Disassembling the carburetor NOTE: Before you start disassembling the carburetor, you should look for a clean work place. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt. –...
Page 193 8-29E – Now, pull the cable disc approx. 5 mm outward and turn it until the throttle valve can be lifted out of the carburetor and detach the rollers at the throttle valve. – Take the throttle valve together with the 4 rollers and the valve paddle out of the carburetor.
Page 194 8-30E – Remove the screw and dismount the throttle-valve sensor When unfastening the screw, be sure to watch out for the bushing NOTE: To dismount the throttle-valve sensor, always remove the screw . After the screw was loosened, the throttle-valve sensor must be adjusted again.
Page 195 8-31E Checking the choke slide It must be easy to actuate the choke slide. The piston of the choke slide must not have any pronounced score marks or deposits. Checking the accelerator pump Check the membranes for cracking or brittleness. Check gaskets for damage.
Page 196 8-32E Assembling the carburetor – Mount the idle-air jet and the main air jet – Place the O-ring in the groove and secure the intake trumpet to the carburetor by means of the 2 screws. – Insert the fuel connection into the carburetor and secure it with the clip.
Page 197 8-33E – Position the float, mount the float hinge pin and secure it by means of the screw. – Check the float level. – Stick the plastic component on the needle jet. – Engage the push rod of the accelerator pump at the lever. –...
Page 198 8-34E – Coat the thread of the screw with Loctite 243 and mount the screw, however, do not tighten it yet. – Push the slide pin inward. At the same time, push the slide lever to the extreme right and tighten the screw –...
Page 199 8-35E – Mount the throttle valve sensor such that the flat spot at the carburetor engages the groove of the throttle valve sensor and secure it by means of the screw. Adjusting the position of the throttle valve sensor NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly.
Page 200 8-36E Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor.
Page 201 8-37E Adjust idling Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel and the mixture control screw .
Page 202 8-38E Adjusting the mixture control screw The mixture control screw is difficult to reach. For this reasons, we have created an appropriate special tool 590.29.034.000. Introduce the special tool into the bore at the carburetor bottom. Press the tool slightly upward and turn the adjusting wheel until the tool engages the slot of the mixture control screw Now, you can go about adjusting the screw.
Page 203 8-39E CARBURETOR - KEIHIN FCR-MX 41...
Page 204 8-40E Disassembling the carburetor Keihin FCR - MX 41 NOTE: Before you start disassembling the carburetor, you should look for a clean workplace. It should offer you enough space to lay out all individual components of the carburetor in perfect order. –...
Page 205 8-41E – Turn the carburetor around, remove the 3 screws and remove the cover of the accelerator pump. NOTE: When dismounting the cover, watch out for the spring and the sealing rings as they may get lost easily. – Remove the 2 sealing rings, the spring and the diaphragm from the pump housing.
Page 206 8-42E – Remove bolts and the throttle sensor NOTE: the throttle sensor should only be dismounted if defective. If the bolts are loosened, the throttle sensor must be adjusted again. – Remove screw and pull the connecting piece out of the carburetor.
Page 207 8-43E Checking the choke slide and hot start knob Choke slide: The choke slide must be easy to actuate . The piston of the choke slide must not have any pronounced score marks or deposits. Hot start knob: The hot start knob must be easily actuated. The piston on the hot start knob may not have any scores or deposits.
Page 208 8-44E Assembling the carburetor Keihin FCR-MX 41 – Mount the idle-air jet and the main air jet – Place the O-ring in the groove and secure the intake trumpet to the carburetor by means of the 2 screws. – Insert the fuel port in the carburetor and fix with screw NOTE: In the mounted state, the connection piece must be easy to turn.
Page 209 8-45E – Position the float and the float needle valve and mount the float hinge pin – Check the float level (see page 8-49). – Mount the float chamber and the gasket, position the bracket for the adjustment screw and fix the float chamber with the screws NOTE: When positioning the float chamber, make sure that the push of the accelerator pump slides into the bore.
Page 210 8-46E – Apply Loctite 243 to the screw and tighten. – Mount the jet needle and fix with the screw – Position the slide cover with the gasket and fasten with the 2 screws – Fix the vent hoses on the float chamber with the 2 bolts...
Page 211 8-47E Adjusting the position of the throttle valve sensor NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly. – Disengage the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve resistance.
Page 212 8-48E Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor.
Page 213 8-49E CARBURETOR – Adjust idling (Keihin FCR-MX 41) Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.
Page 215: Trouble Shooting
9-1E TROUBLE SHOOTING INDEX TROUBLE SHOOTING (SX, SXC, SC, SMC) ....9-2 TROUBLE SHOOTING (LC4 COMPETITION) ....9-4 TROUBLE SHOOTING (LC4) .
Page 217 9-2E TROUBLE SHOOTING – SX, SXC, SC, SMC TROUBLE CAUSE REMEDY Engine will not start Operating error Switch on ignition, switch on emergency OFF switch, open fuel tap, tank fuel, do not use choke i.e. the hotstart device. attention starting information (see driving...
Page 218 9-3E TROUBLE CAUSE REMEDY Engine will not reach full Fuel supply partically interrupted or Clean and check fuel system as well as carburettor power carburettor dirty Float is not tight, or no axial play Replace or abrade the float Air filter very dirty Clean or replace air filter Exhaust leaking or blocked Check if exhaust is damaged, replace glas fibre yarn in...
Page 219 9-4E TROUBLE SHOOTING – LC4 COMPETITION TROUBLE CAUSE REMEDY Engine will not start Operating error Switch on ignition, switch on emergency OFF switch, open fuel tap, tank fuel, do not use choke i.e. the hotstart device. Pay attention to starting off information (see driving instructions).
Page 220 9-5E TROUBLE CAUSE REMEDY Engine does not rev high Carburetor fuel level too high Dismount carburetor and check if worn out because Float needle is dirty or worn out Replace float needle Float leaks Replace float cold starting system Adjust choke cable. permanently activated due to a lack of play in the choke cable.
Page 221 9-6E TROUBLE CAUSE REMEDY The neutral indicator lamp Defective indicator lamp. Replace indicator lamp. doesn’t light up when the motorcycle into neutral. Defective idle switch. Connect the cable to ground. The neutral switch must be replaced if the indicator lamp lights up. Loose connections, defective cable.
Page 222 9-7E TROUBLE SHOOTING LC4 TROUBLE CAUSE REMEDY Engine doesn’t crank. Turn on the ignition, switch the gear to neutral and switch Operating errror the emergency OFF switch on. Discharged battery. Recharge the battery and investigate the causes for discharging. Defect ignition lock or emergency Check ignition lock and emergency OFF switch.
Page 223 9-8E TROUBLE CAUSE REMEDY Engine fails to idle Glogged idling jet Disassemble carburetor and clean jets Uncorrect adjustment of adjusting Adjust carburetor screws on carburetor Defective spark plug Replace spark plug Defective ignition system Check ignition system Engine does not rev high Carburetor fuel level too high Dismount carburetor and check if worn out because...
Page 224 9-9E TROUBLE CAUSE REMEDY All switched on lamps Voltage regulator faulty Remove seat and check connections. Check voltage regulator blown out Headlight parking Blown fuse Replace fuse (below the headlight mask). light fail Flasher lights, brake light, Blown fuse Replace fuse (below the headlight mask). fan and horn fail The NEUTRAL lamp is Defect indicator lamp.
Page 225 10-1F CHASSIS INDEX DISMOUNTING/MOUNTING THE CHASSIS COMPONENTS DISMOUNTING/MOUNTING THE ROCKER ARM AND SHOCK ABSORBER ..10-2 DISMOUNTING/MOUNTING THE FORK LEGS ......10-3 DISMOUNTING/MOUNTING THE SWING ARM .
Page 227 10-2E Dismounting/mounting the rocker arm and shock absorber – Jack up the motorcycle (place on a firm and even surface), unscrew and remove the two nuts and the shock absorber screw the rocker arm – Slightly lift the rear wheel and pull out the bolt –...
Page 228 10-3F Dismounting/mounting the fork legs – See Owner's Manual to remove the front wheel. – Remove the bracket for the brake hose on the left fork protector. – Loosen the clamp screws on both sides of the lower and upper triple clamp.
Page 229 10-4E Replacing the swing arm bearing: – To dismount the swing arm, see page 10-3 Chassis. – Remove all 4 seal ring tappets (does not require a tool). – Pry out all of the shaft seal rings with a screwdriver without damaging the swing arm and remove the stop disks –...
Page 230 10-5F Replacing the steering head bearing – See Owner's Manual to remove the headlight mask. – Remove the lower 4 and the upper fixing screws and take off the fender. NOTE: Remove the lower screws with the sleeves and the upper screws with the distance bushings and shims.
Page 231 10-6F Replacing the chain, chain guide, pinion and rear sprocket – Open the lock on the chain joint with pliers, remove the chain link and pull the chain from the rear sprocket. NOTE: – If you cannot remove the chain link by hand, hold the chain while you hammer the chain link out with a driver.
Page 232 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 O NOT REST THE WHEEL ON THE BRAKE DISK –...
Page 233 10-8E Overhauling the rocker arm – See page 10-2 Chassis to dismount the rocker arm. – Remove all 4 seal ring tappets (does not require a tool). – Pry out all of the shaft seal rings with a screwdriver without damaging the housing.
Page 234 10-9F Opening the chain with a separating/rivet tool NOTE: an X-ring chain, type 520 HV (5/8x1/4“), is used for the KTM LC4 from 2005 models. You will need special tool 600.29.020.000 to separate or rivet the chain according to the manufacturer's specifications.
Page 235: Technical Specifications
11-1E TECHNICAL SPECIFICATIONS INDEX MODEL 1998 TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC ....11-3 TECHNICAL SPECIFICATIONS – CHASSIS 400/540 SXC ....11-4 TECHNICAL SPECIFICATIONS –...
Page 237 11-2F INDEX MODEL 2001 TECHNICAL SPECIFICATIONS – ENGINE 620 SC, SUPERMOTO ... . 11-36 TECHNICAL SPECIFICATIONS – CHASSIS 620 SC, SUPERMOTO ... 11-37 TECHNICAL SPECIFICATIONS –...
Page 238 11-2Fb INDEX MODEL 2005 TECHNICAL SPECIFICATIONS – ENGINE 625 SXC / SMC ....11-67 TECHNICAL SPECIFICATIONS – CHASSIS 625 SXC / SMC ....11-68 TECHNICAL SPECIFICATIONS –...
Page 239 11-3E TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC ‘98 Engine 400 LC4 540 LC4 Design Liquid-cooled single cylinder 4-stroke engine with and without balancer shaft Displacement 398 cm 538,5 cm Bore / Stroke 89 / 64 mm 95 / 76 mm Ratio 10,8 : 1 11,1 : 1...
Page 240 11-4E TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC ‘98 400/540 SXC Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 285/320 mm (11,2/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø...
Page 241 11-5E TECHNICAL SPECIFICATIONS – ENGINE 400/620 SX, SC ‘98 Engine 400 LC4 620 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 cm 609 cm Bore / Stroke 89 / 64 mm 101 / 76 mm Ratio 10,8 : 1 SX: 11,5 : 1 SC: 10,4 : 1...
Page 242 11-6E TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SX, SC ‘98 620 SX 400/620 SC Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 285/320 mm (11,2/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø...
Page 243 11-7E TECHNICAL SPECIFICATIONS – ENGINE 620 LC4 COMPETITION ‘98 Engine 620 LC4 COMP. Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 609 cm Bore / Stroke 101 / 76 mm Ratio 10,4 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 244 11-8E TECHNICAL SPECIFICATIONS - CHASSIS 620 LC4 COMP. ‘98 620 LC4 COMP. Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280 / 320 mm (11,0 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø...
Page 245 11-9E TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘98 Engine 400 LC4 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 624.6 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm Ratio 10,8 : 1 11 : 1...
Page 246 11-10E BASIC CARBURETOR SETTING 400 LC4 400 LC4 25 kW 31 kW Carburetor PHM 38 ND PHM 38 ND Carburetor setting number 100197 100197 Main jet Needle jet AR 264 AR 264 Idling jet Jet needle K 23 K 23 Needle position from top 2 nd 2 nd...
Page 247 11-11E TECHNICAL SPECIFICATIONS - CHASSIS 400 / 640 LC4 ‘98 400/640 LC4 ‘98 Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280 / 320 mm (11 / 12.6 in) Rear suspension Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc 300 mm (11.8 in), brake caliper floated...
Page 248 11-12E TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘98 640 ADVENTURE R Frame Central chrome-moly-steel frame Fork WP-Extreme Ø 50 mm Wheel travel front/rear 300 / 320 mm (11,8 / 12,6 in) Rear suspension Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated...
Page 249 11-13E TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE-E ‘98 Type 640 DUKE last edition Frame Central chrome-moly-steel frame Fork type WP - 4054 Roma Top adjuster wheel travel 140 mm (5,5 in) standard adjustment compression driver only = 14, with passenger = 14...
Page 250 11-14E TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC, 620 SX ‘99 Engine 400 SXC 540 SXC 620 SX Design Liquid-cooled single cylinder 4-stroke engine Displacement 398 ccm 538,5 ccm 609 ccm Bore / Stroke 89 / 64 mm 101 / 76 mm Ratio 10,8 : 1 11,3 : 1...
Page 251 11-15E TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC, 620 SX ‘99 400/540 SXC 620 SX Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280/320 mm (11/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 252 11-16E TECHNICAL SPECIFICATIONS – ENGINE 400/620 Supercompetition ‘99 Engine 400 LC4 620 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 ccm 609 ccm Bore / Stroke 89 / 64 mm 101 / 76 mm Ratio 10,8 : 1 10,4 : 1 Fuel unleaded premium gasoline with a least RON 95...
Page 253 11-17E TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 Supercompetition ‘99 400 SC 620 SC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 295 / 320 mm (11,6 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 254 11-18E TECHNICAL SPECIFICATIONS – ENGINE 620 LC4 COMPETITION ‘99 Engine 620 LC4 COMPETITION Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 609 cm Bore / Stroke 101 / 76 mm Ratio 10,4 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 255 11-19E TECHNICAL SPECIFICATIONS - CHASSIS 620 LC4 COMPETITION ‘99 620 LC4 COMPETITION Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280 / 320 mm (11,0 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø...
Page 256 11-20E TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘99 Engine 400 LC4-E 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 625 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm Ratio 10,8 : 1 11 : 1...
Page 257 11-21E ( R ) TECHNICAL SPECIFICATIONS - CHASSIS 400 LC4 / 640 LC4 / SUPERMOTO ‘99 400 LC4 / 640 LC4 640 Supermoto 400 LC4 / 640 LC4 Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280 / 320 mm (11 / 12.6 in) 250 / 290 mm (10 / 11.4 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear- swing-arm with needle bearing...
Page 258 11-22E TECHNICAL DATA – ENGINE 640 LC4-E ADVENTURE R ‘99 Engine 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain...
Page 259 11-23E TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘99 640 ADVENTURE R Frame Central chrome-moly-steel frame Fork WP-Extreme Ø 50 mm Wheel travel front/rear 300 / 320 mm (11,8 / 12,6 in) Rear suspension Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated...
Page 260 11-24E TECHNICAL DATA – ENGINE KTM 640 DUKE ‘99 Type 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95...
Page 261 11-25E TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE ‘99 Frame Central chrome-moly-steel frame Fork type ....... . WP - USD 43 Top adjuster 518T780 wheel travel .
Page 262 11-26E TECHNICAL SPECIFICATIONS – ENGINE 400/620 SC, Supermoto 2000 Engine 400 LC4 620 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 ccm 609 ccm Bore / Stroke 89 / 64 mm 101 / 76 mm Ratio 10,8 : 1 10,4 : 1 Fuel...
Page 263 11-27E TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SC, Supermoto 2000 400/620 SC 620 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 295 / 320 mm (11.6 / 12.6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc...
Page 264 11-28E TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2000 Type 400 LC4-E 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 624,6 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm Ratio 10,8 : 1...
Page 265 11-29E BASIC CARBURETOR SETTING 400 LC4-E 400 LC4-E 400 LC4-E 25 kW 31 kW Type PHM 38 ND PHM 38 ND BST40-225 Carb.-setting number 100197 100197 090298 Main jet 142,5 Needle jet AR 264 AR 264 689 X-6 Idling jet Jet needle K 23 K 23...
Page 266 11-30E TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2000 400 LC4-E 640 LC4-E 640 LC4-E SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 270 / 300 mm (10,6 / 11,8 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake...
Page 267 11-31E TECHNICAL SPECIFICATIONS - CHASSIS LC4 ADVENTURE R 640 2000 LC4 Adventure R 640 Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280/320 mm (11/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 268 11-32E TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE 2000 Frame Central chrome-moly-steel frame Fork type ....... . WP - USD 43 Multi adjuster 0518U795 wheel travel .
Page 269 11-33E TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE 2000 USA, AUS Frame Central chrome-moly-steel frame Fork type ....... . WP - USD 43 Top adjuster 518T780 wheel travel .
Page 270 11-34E TECHNICAL SPECIFICATIONS – ENGINE 400 SXC USA 2000 Engine 400 SXC Design Liquid-cooled single cylinder 4-stroke engine Displacement 398 ccm Bore / Stroke 89 / 64 mm Ratio 10,8 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 271 11-35E TECHNICAL SPECIFICATIONS - CHASSIS 400 SXC USA 2000 400 SXC Frame Central chrome-moly-steel frame Fork White Power – EXTREME Wheel travel front/rear 295 / 320 mm (11,6 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 272 11-36E TECHNICAL SPECIFICATIONS – ENGINE 620 SC, 620 SC SUPERMOTO 2001 Engine Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 609 ccm Bore / Stroke 101 / 76 mm Ratio 10,4 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 273 11-37E TECHNICAL SPECIFICATIONS - CHASSIS 620 SC, 620 SC SUPERMOTO 2001 620 SC 620 SC SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 295 / 320 mm (11,6 / 12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated...
Page 274 11-38E TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2001 Type 400 LC4-E 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 624,6 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm Ratio 10,8 : 1...
Page 275 11-39E BASIC CARBURETOR SETTING 400 LC4-E 400 LC4-E 400 LC4-E 25 kW 31 kW Type PHM 38 ND PHM 38 ND BST40-225 Carb.-setting number 100197 100197 090298 Main jet 142,5 Needle jet AR 264 AR 264 689 X-6 Idling jet Jet needle K 23 K 23...
Page 276 11-40E TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001 400 LC4-E 640 LC4-E 640 LC4-E SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 270 / 300 mm (10,6 / 11,8 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake...
Page 277 11-41E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2001 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD Wheel travel front/rear 275/300 mm (10,5/12 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 278 11-42E TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE 2001 Frame Central chrome-moly-steel frame Fork type ....... . WP - USD 43 Multi adjuster 0518U795 wheel travel .
Page 279 11-43E TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE 2001 USA, AUS Frame Central chrome-moly-steel frame Fork type ....... . WP - USD 43 Top adjuster 518T780 wheel travel .
Page 280 11-44E TECHNICAL SPECIFICATIONS – ENGINE 625 SC, 625 SC SUPERMOTO 2002 Engine 625 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 281 11-45E TECHNICAL SPECIFICATIONS - CHASSIS 625 SC, 625 SC SUPERMOTO 2002 625 SC 625 SC SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) 270 / 320 (10,8 / 12.8 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake...
Page 282 11-46E TECHNICAL DATA – ENGINE 640 LC4 2002 Engine 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 624,6 ccm Bore / Stroke 101 / 78 mm Ratio 11 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 283 11-47E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake...
Page 284 11-48E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2002 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear 275/300 mm (10,5/12 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with need bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 285 11-49E TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2002 Frame Central chrome-moly-steel frame Fork type ......WP 4357 ROMA 0518716 wheel travel .
Page 286 11-50E TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003 Engine 625 SXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,5 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 287 11-51E TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003 625 SXC Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated Front brake disc...
Page 288 11-52E TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2003 Engine 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11.5 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing...
Page 289 11-53E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2003 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power – Up Side Down 4860 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) 265 / 310 mm (10,4 / 12,2 in) Rear suspension...
Page 290 11-54E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2003 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear 275/300 mm (10,5/12 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø...
Page 291 11-55E TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2003 Frame Central chrome-moly-steel frame Fork type ....... . . WP 4357 ROMA 0518X732 wheel travel .
Page 292 11-56E TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2003 Engine 660 SMC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 653 ccm Bore / Stroke 102 / 80 mm Ratio 11,5 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 293 11-57E TECHNICAL SPECIFICATIONS - CHASSIS 660 SMC 2003 660 SMC Frame Central chrome-moly-steel frame Fork White Power 4860 MXMA Wheel travel front/rear 265 / 310 mm (10,6 / 12,4 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, and 4 piston brake caliper Front brake disc...
Page 294 11-58E TECHNICAL SPECIFICATIONS – ENGINE 625 SXC USA 2004 Engine 625 SXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,7 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 295 11-59E TECHNICAL SPECIFICATIONS – ENGINE 625 SXC EUROPE 2004 Engine 625 SXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,7 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 296 11-60E TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2004 625 SXC Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated Front brake disc...
Page 297 11-61E TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto 2004 Engine 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11.7 : 1 Fuel unleaded premium gasoline with at least RON 95 (USA = Premium RON 91) (RON 80-94 for other ignition curve Valve timing...
Page 298 11-62E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2004 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power – Up Side Down 4860 MXMA Wheel travel front/rear 275 / 290 mm (11 / 11.6 in) 265 / 300 mm (10.6 / 12 in) Rear suspension...
Page 299 11-63E TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2004 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear 275/300 mm (10,5/12 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake, 2 perforated brake discs Ø...
Page 300 11-64E TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2004 Frame Central chrome-moly-steel frame Fork type ....... . . WP 43 ROMA 1418Y755 wheel travel .
Page 301 11-65E TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2004 Engine 660 SMC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 654 ccm Bore / Stroke 102 / 80 mm Ratio 11,7 : 1 Fuel unleaded premium gasoline with a least RON 95 (USA = Premium RON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 302 11-66E TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC 2004 660 SMC Frame Central chrome-moly-steel frame Fork White Power 4860 MXMA Wheel travel front/rear 265 / 300 mm (10,6 / 11,8 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, and 4 piston brake caliper Front brake disc...
Page 303 11-67F TECHNICAL SPECIFICATIONS – ENGINE 625 SXC / SMC 2005 ENGINE 625 SXC / SMC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 cm Bore / Stroke 101 / 78 mm Ratio 11,7 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 304 11-68F TECHNICAL SPECIFICATIONS – CHASSIS 625 SXC / SMC 2005 625 SXC 625 SMC Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA White Power 4860 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) 265 / 300 mm Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake...
Page 305 11-69F TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE 2005 ENGINE 640 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 cm Bore / Stroke 101 / 78 mm Ratio 11,7 : 1 Fuel unleaded premium gasoline with at least RON 95 (USA = Premium RON 91) (RON 80-94 for other ignition curve) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain...
Page 306 11-70F TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 2005 640 LC4 ENDURO 640 LC4 SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power - Up Side Down 4860 MXMA Wheel travel front/rear 275 / 275 mm 275 / 260 mm Rear suspension Central shock absorber (WP BAVP) with PRO-LEVER linkage to rear- swing-arm with needle bearing...
Page 307 11-71F TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 ADVENTURE 2005 CHASSIS 640 LC4 ADVENTURE Frame Central chrome-moly-steel frame Fork White Power Up Side Down MXMA 4860 Wheel travel front/rear 275/300 mm (10.5/12 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake, 2 perforated brake discs Ø...
Page 308 11-72F TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE 2005 CHASSIS 640 DUKE II Frame Central chrome-moly-steel frame Fork type ......WP 4357 MXMA 05187A03 wheel travel .
Page 309 11-73F TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2005 ENGINE 660 SMC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 654 ccm Bore / Stroke 102 / 80 mm Ratio 11,7 : 1 Fuel unleaded premium gasoline with a least RON 95 (USA = Premium RON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft...
Page 310 11-74F TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC 2005 CHASSIS 660 SMC Frame Central chrome-moly-steel frame Fork White Power 4860 MXMA Wheel travel front/rear 275 / 260 mm (10.8 / 10.2 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, and 4 piston brake caliper Front brake disc...
Page 311 11-75F TIGHTENING TORQUE - ENGINE Hexagon nut at primary gear M20x1,5 Loctite 243 + 170 Nm Collar nut flywheel (LC4, ADVENTURE, DUKE) M16x1,25 links 150 Nm Collar nut flywheel (SC, SXC) M12x1 left 60 Nm Hexagon nut for inner clutch hub M18x1,5 Loctite 243 + 90 Nm Collar bolt clutch springs...
Page 312 11-76F TIGHTENING TORQUE - CHASSIS Collar nut front axle M16x1,5, M17 40 Nm Collar nut / collar screw front axle M24x1,5 40 Nm Collar screw front axle (Adventure Supermoto) M24x1,5 60 Nm Collar screw front axle (400 SXC) 40 Nm Collar nut rear axle M20x1,5 80 Nm...
Page 313 11-77F ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play except Rally ......0.10 - 0.20 mm axial play Rally only .
Page 315 12-1E PERIODIC MAINTENANCE SCHEDULE INDEX MODEL 1998 PERIODIC MAINTENANCE SCHEDULE SX, SXC, SC ....12-2 PERIODIC MAINTENANCE SCHEDULE LC4 COMPETITION, LC4 ..12-3 PERIODIC MAINTENANCE SCHEDULE ADVENTURE-R ... .12-4 PERIODIC MAINTENANCE SCHEDULE DUKE-E .
Page 316 12-1Fb INDEX MODEL 2005 PERIODIC MAINTENANCE SCHEDULE 625 SXC / SMR ....12-38 PERIODIC MAINTENANCE SCHEDULE 640 LC4, 640 LC4 SUPERMOTO ..12-40 PERIODIC MAINTENANCE SCHEDULE 640 LC4 ADVENTURE .
Page 317 12-2E PERIODIC MAINTENANCE SCHEDULE rider dealer SX, SXC, SC 9.97 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter unit...
Page 318 12-3E PERIODIC MAINTENANCE SCHEDULE rider dealer 400/640 LC4’98 620 LC4 Comp.’98 4. 98 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil...
Page 319 12-4E PERIODIC MAINTENANCE SCHEDULE rider dealer Adventure-R 3.98 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert...
Page 320 12-5E PERIODIC MAINTENANCE SCHEDULE rider dealer DUKE-E 2.98 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert...
Page 321 12-6E PERIODIC MAINTENANCE SCHEDULE rider dealer 2.99 620 SX 400/540 SXC 400/620 SC IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil...
Page 322 12-7E PERIODIC MAINTENANCE SCHEDULE rider dealer 400/640 LC4 ’99 400/640 LC4 ’99 620 LC4 Comp.’99 620/640 Supermoto ‘99 10. 98 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil...
Page 323 12-8E PERIODIC MAINTENANCE SCHEDULE rider dealer Adventure 09.98 IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert...
Page 325 12-9E PERIODIC MAINTENANCE SCHEDULE rider dealer Duke 5.99 IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks...
Page 326 12-10E PERIODIC MAINTENANCE SCHEDULE 620 SC after / every 1. Service after after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 327 12-11E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 328 12-12E 400/640 LC4-E PERIODIC MAINTENANCE SCHEDULE 640 LC4 Adventure 2. Service after 1. Service 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or after 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 329 12-13E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 330 12-14E PERIODIC MAINTENANCE SCHEDULE 640 Duke II 2. Service after 1. Service 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or after 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 331 12-15E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every once a year for com- start cleaning petition use Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper function Check horn for proper function Lubricate and adjust actuating cables and nipples...
Page 332 12-16E 625 SC PERIODIC MAINTENANCE SCHEDULE 2002 625 SC SUPERMOTO after / every 1. Service after after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug...
Page 333 12-17E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 334 12-18E 640 LC4, LC4 SUPERMOTO PERIODIC MAINTENANCE SCHEDULE 2002 640 LC4 ADVENTURE 1. Service 2. Service after after 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or 1000 km once a year Change engine oil and oil filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 335 12-19E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 336 12-20E PERIODIC MAINTENANCE SCHEDULE 2002 640 Duke II 2. Service after 1. Service 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or after 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 337 12-21E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every once a year start cleaning 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 adjust actuating cables and nipples Bleed fork legs in regular intervals...
Page 338 12-22E 625 SXC PERIODIC MAINTENANCE SCHEDULE 2003 660 SMC after / every 1. Service after after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 339 12-23E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 340 12-24E 640 LC4, 640 LC4 SUPERMOTO PERIODIC MAINTENANCE SCHEDULE 2003 640 LC4 ADVENTURE 2. Service after 1. Service after 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 341 12-25E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use 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 adjust actuating cables and nipples...
Page 342 12-26E PERIODIC MAINTENANCE SCHEDULE 2003 640 Duke 2nd Service after 1st Service 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or after 1000 km once a year Change engine oil, oil filters, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 343 12-27E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every once a year start cleaning 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 adjust actuating cables and nipples Bleed fork legs in regular intervals...
Page 344 12-28E PERIODIC MAINTENANCE SCHEDULE 2004 625 SXC USA after / every 1. Service after after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 345 12-29E PERIODIC MAINTENANCE SCHEDULE 2004 625 SXC USA IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km at least every 2 years or 25 hours once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer...
Page 346 12-30E PERIODIC MAINTENANCE SCHEDULE 2004 625 SXC EUROPE after / every 1. Service after 1000 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km...
Page 347 12-31E PERIODIC MAINTENANCE SCHEDULE 2004 625 SXC EUROPE IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km at least every 2 years or 25 hours once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer...
Page 348 12-32E 640 LC4, 640 LC4 SUPERMOTO PERIODIC MAINTENANCE SCHEDULE 640 LC4 ADVENTURE 2. Service after 1. Service after 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 349 12-33E 640 LC4, 640 LC4 SUPERMOTO PERIODIC MAINTENANCE SCHEDULE 640 LC4 ADVENTURE VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation...
Page 350 12-34E PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC after / every 1. Service after after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement...
Page 351 12-35E PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km at least every 2 years or 25 hours once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer...
Page 352 12-36E PERIODIC MAINTENANCE SCHEDULE 640 Duke II 2nd Service after 1st Service 5000 km, then A washed motorcycle can be checked more quickly which saves money! every 5000 km or after 1000 km once a year Change engine oil, oil filters, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km...
Page 353 12-37E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every once a year start cleaning 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 adjust actuating cables and nipples Bleed fork legs in regular intervals...
Page 354 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceed by moor than 500 km. Maintenance work done by KTM authorised workshops is not a substitute of care and checks done by the rider!
Page 355 12-39F IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 at least once every 2 years km or 25 a year or 20000 km hours Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements...
Page 356 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceed by moor than 500 km. Maintenance work done by KTM authorised workshops is not a substitute of care and checks done by the rider!
Page 357 12-41F IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least every 2 years or once a year 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
Page 358 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
Page 359 12-43F IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least every 2 years once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
Page 360 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
Page 361 12-45F IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least every 2 years once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of the silencers Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray...
Page 362 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
Page 363 12-47F IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2 years every 2500 km at least or 25 hours once a year or 20,000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements...
Page 365: Wiring Diagrams
13-1E WIRING DIAGRAMS INDEX MODEL1998 WIRING DIAGRAM 400 / 540 SXC ..... .13-3 WIRING DIAGRAM 400 / 620 SC (For Competition) ..13-5 WIRING DIAGRAM 400 / 620 SC (For Australia) .
Page 366 13-2F INDEX MODEL 2001 WIRING DIAGRAM 620 SC / 620 SC SUPERMOTO .....13-37 WIRING DIAGRAM 640 LC4 ADVENTURE ......13-39 WIRING DIAGRAM 640 DUKE .
Page 367 13-2Fb INDEX DETAIL WIRING DIAGRAMS 640 LC4 ADVENTURE 2003-2005 SWITCHES ..........13-64 START SYSTEM .
Page 368 13-2Fc INDEX DETAIL WIRING DIAGRAMS 625 SMC 2005 SWITCHES ..........13-94 START-/CHARGING SYSTEM .
Page 369 13-2Fd INDEX DETAIL WIRING DIAGRAMS 660 SMC 2005 SWITCHES ..........13-123 CDI, CHARGING SYSTEM .
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Page 420 13-53E Kabelstrangnummer: Land: Modell Datum, Name: Dateiname: SERVICE SERVICE 640 LC4 2002 vorne: 584.11.175.300 400/640 LC4-E 2002 DIV. LÄNDER ax ax 10.05.01 KE LC42002 hinten: 584.11.176.200 MOTORCYCLE START NOT- ge-bl ge-bl bl-s ELECTRONIC ge-bl POWER- CONTROL bl-w ge-bl ge-bl bl-s ge-s ge-bl KOKUSAN...
Page 421 13-54E Deutsch Englisch Italienisch Franz sisch 1 Scheinwerfer 1 headlight 1 faro 1 phare 2 Standlicht 2 parking light 2 luce di posizione 2 feu de position 3 Blinker li vo 3 blinker left front 3 lampegg. ant. sn. 3 clignoteur av. gauche 4 Blinker re vo 4 blinker right front 4 lampegg.
Page 422 13-55E Kabelstrangnummer: Land: Modell Datum, Name: Dateiname: SERVICE SERVICE 640 LC4 USA 2002 vorne: 584.11.175.300 640 LC4-E USA 2002 ax ax 10.05.01 KE LC42002 hinten: 584.11.176.200 MOTORCYCLE START NOT- ge-bl ge-bl ge-bl ge-bl bl-s ge-s ge-bl KOKUSAN bl-w ge-bl KOKUSAN ge-r bl-w KOKUSAN...
Page 423 13-56E Deutsch Englisch Italienisch Franz sisch 1 Scheinwerfer 1 headlight 1 faro 1 phare 2 Standlicht 2 parking light 2 luce di posizione 2 feu de position 3 Blinker li vo 3 blinker left front 3 lampegg. ant. sn. 3 clignoteur av. gauche 4 Blinker re vo 4 blinker right front 4 lampegg.
Page 424 13-57E 660 SMC 2003...
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Page 501 13-134F NOTE to the connector designations: The connector designations are comprised of letters and numbers - e.g.: C_AA1/20 – The 1st position C stands for connector (connector). – The 2nd and 3rd positions AA stand for the connector type. – The 4th position numbers the same type of connector if the connector is used for different applications.

KTM 400-660 LC4 1998-2005 Repair Manual

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