KTM 400 EXC AUS 2011 Repair Manual page 269

INDEX
Compr ... ion d.mpinl, low-.p •• d
shock absorber, adjusting .......•............. 40
Cool.nt
draining ................................ 179
refilling ....•..•......•..•...•..•........ 180
Coolant l.v.1
checking ............................. 178-179
COOlinl.,st.m . . . . . . . . . . . .. . .. . . . .. .. . . . . . . .. 178
Cylind.r - Nika.iI· coatinl .......................
126
D
Di ..... mblinl the .nlin.
E
cl utch cover, removi ng ...................... 110
clutch disks, disassembling ................... 111
free wheel gear, removing .................... 114
gear oil screen, removing ..................... 104
gear oil, draining .......................... 104
left
section of the engine case, removing .......... 115
oil filter, removing ......................... 104
oil pumps, removing ........................ 114
outer clutch hub, removing ......•............ 111
preparations ................•............ 104
primary gear, removing ..........•..•..•.....
removing the oil pump gears ......•..•..•.....
suction pump, removing .........•..•..•.....
torque limiter, removing .........•..•..•.....
transmission shafts, removing ........•..•.....
114
113
109
112
116
Enlin.
installing
removing
102
101
Enlin. - work on individual parts
autodecompressor, assembling ................ .
autodecompressor, disassembling .............. .
clutch, checking .......................... .
countershaft, assembling .................... .
countershaft, disassembly ................... .
crankshaft seal ring in the clutch cover, removing ... .
crankshaft seal ring, installing in clutch cover ...... .
cylinder -
Nika.iI-
coating ................... .
cylinder head, checking .........•............
electric starter mode, checking ....•............
freewheel, checking ............•..•..•.....
freewheel, installing ............•..•..•.....
freewheel, removing ..................•.....
kickstarter shaft, premounting ...........•.....
left section of the engine case, working on ...•.....
main shaft, assembling ................•.....
main shaft, disassembling ..............•.....
oil pressure regulator valve, installing ........... .
oil pressure regulator valve, removing ........... .
oil pumps, checking ....................... .
piston ring end gap, checking ................. .
piston, checking/measuring ......•............
right engi ne case section ........•............
rocker arm shafts, checking ......•............
rocker arm, installing ...................... .
rocker arm, removing ...................... .
shift shaft, preassembling ................... .
timing assembly, checking ................... .
129
128
135
139
138
121
121
126
133
141
142
142
142
140
119
138
137
121
121
128
127
127
118
134
135
131
137
130
269
timing chain sprocket, installing ................ 124
timing chain sprocket, removing ................ 123
timing chain tensioner, preparing for installation ..... 130
valves, installing ........................... 134
valves, removing ...............•........... 131
water pump, installing ...........•......•.... 122
water pump, removing . . . . . . . . . . . . • . . • . . . . . .. 122
Engine - work on the individual parts
balancer shaft, checking ..........•..•....... 123
camshaft bearing, changing ................... 132
camshaft, checking . . . . . . . . . . . . . . . . . . . . . . . .. 129
connecting rod, conrad bearing and crank pin, changing 124
crankshaft run-out at the bearing pin, checking ..... 126
cylinder, checking/measuring .................. 126
piston/cylinder - determining the mounting clearance . 128
shift mechanism, checking ................... 136
spring length of oil pressure regulator valve, checking . 121
transmission, checking ...................... 139
valve spring seat, checking ................... 133
valve springs, checking ...................... 133
valves, checking ........................... 132
Enlin. a ... mbl,
alternator cover, installing .................... 157
balance weight, installing .................... 153
camshaft, installing ........................ 156
clutch cover, installing ...................... 150
cylinder head, installing .........•......•.... 155
filling up with engine oil .........•......•.... 159
filling up with gear oil ...........•......•.... 159
kickstarter idler gear, installing .....•......•.... 148
kickstarter shaft, installing ........•......•.... 148
kickstarter, installing ............•......•.... 151
locking lever, installing .......•...•..•..•.... 147
oil filter, installing .......•..•...•..•....... 159
oil pump gears, installing ...•..•...•..•....... 147
oil pumps, installing .........•...•..•....... 146
piston, installing ...........•...•..•....... 153
primary gear nut, installing ........•..•....... 150
rotor, installing .................•..•....... 153
shift drum locating unit, installing .........•.... 147
shift drum, installing ...................•.... 145
shift forks, installing ...................•.... 144
shift lever, installing ............•......•.... 158
shift rails, installing ............•......•.... 145
shift shaft, installing ............•......•.... 147
spark plug, installing ............•......•.... 158
starter idler gear, installing ................... 148
starter motor, installing ...................... 158
suction pump, installing ..................... 151
timing chain guide rail, installing ............... 153
timing chain securing guide, installing ............ 152
timing chain tensioning rail, installing ............ 152
timing chain, installing .................•.... 152
torque limiter, installing ................•.... 148
transmission shafts, installing .....•........... 144
valve clearance, adjusting ........•........... 157
valve cover, installing ...........•........... 158
water pump cover, installing ......•......•.... 151
Engin. di ••••• mbl'
alternator cover, removing .....•...•..•....... 106
INDEX
Compr ... ion d.mpinl, low-.p •• d
shock absorber, adjusting .......•............. 40
Cool.nt
draining ................................ 179
refilling ....•..•......•..•...•..•........ 180
Coolant l.v.1
checking ............................. 178-179
COOlinl.,st.m . . . . . . . . . . . .. . .. . . . .. .. . . . . . . .. 178
Cylind.r - Nika.iI· coatinl .......................
126
D
Di ..... mblinl the .nlin.
E
cl utch cover, removi ng ...................... 110
clutch disks, disassembling ................... 111
free wheel gear, removing .................... 114
gear oil screen, removing ..................... 104
gear oil, draining .......................... 104
left
section of the engine case, removing .......... 115
oil filter, removing ......................... 104
oil pumps, removing ........................ 114
outer clutch hub, removing ......•............ 111
preparations ................•............ 104
primary gear, removing ..........•..•..•.....
removing the oil pump gears ......•..•..•.....
suction pump, removing .........•..•..•.....
torque limiter, removing .........•..•..•.....
transmission shafts, removing ........•..•.....
114
113
109
112
116
Enlin.
installing
removing
102
101
Enlin. - work on individual parts
autodecompressor, assembling ................ .
autodecompressor, disassembling .............. .
clutch, checking .......................... .
countershaft, assembling .................... .
countershaft, disassembly ................... .
crankshaft seal ring in the clutch cover, removing ... .
crankshaft seal ring, installing in clutch cover ...... .
cylinder -
Nika.iI-
coating ................... .
cylinder head, checking .........•............
electric starter mode, checking ....•............
freewheel, checking ............•..•..•.....
freewheel, installing ............•..•..•.....
freewheel, removing ..................•.....
kickstarter shaft, premounting ...........•.....
left section of the engine case, working on ...•.....
main shaft, assembling ................•.....
main shaft, disassembling ..............•.....
oil pressure regulator valve, installing ........... .
oil pressure regulator valve, removing ........... .
oil pumps, checking ....................... .
piston ring end gap, checking ................. .
piston, checking/measuring ......•............
right engi ne case section ........•............
rocker arm shafts, checking ......•............
rocker arm, installing ...................... .
rocker arm, removing ...................... .
shift shaft, preassembling ................... .
timing assembly, checking ................... .
129
128
135
139
138
121
121
126
133
141
142
142
142
140
119
138
137
121
121
128
127
127
118
134
135
131
137
130
269
timing chain sprocket, installing ................ 124
timing chain sprocket, removing ................ 123
timing chain tensioner, preparing for installation ..... 130
valves, installing ........................... 134
valves, removing ...............•........... 131
water pump, installing ...........•......•.... 122
water pump, removing . . . . . . . . . . . . • . . • . . . . . .. 122
Engine - work on the individual parts
balancer shaft, checking ..........•..•....... 123
camshaft bearing, changing ................... 132
camshaft, checking . . . . . . . . . . . . . . . . . . . . . . . .. 129
connecting rod, conrad bearing and crank pin, changing 124
crankshaft run-out at the bearing pin, checking ..... 126
cylinder, checking/measuring .................. 126
piston/cylinder - determining the mounting clearance . 128
shift mechanism, checking ................... 136
spring length of oil pressure regulator valve, checking . 121
transmission, checking ...................... 139
valve spring seat, checking ................... 133
valve springs, checking ...................... 133
valves, checking ........................... 132
Enlin. a ... mbl,
alternator cover, installing .................... 157
balance weight, installing .................... 153
camshaft, installing ........................ 156
clutch cover, installing ...................... 150
cylinder head, installing .........•......•.... 155
filling up with engine oil .........•......•.... 159
filling up with gear oil ...........•......•.... 159
kickstarter idler gear, installing .....•......•.... 148
kickstarter shaft, installing ........•......•.... 148
kickstarter, installing ............•......•.... 151
locking lever, installing .......•...•..•..•.... 147
oil filter, installing .......•..•...•..•....... 159
oil pump gears, installing ...•..•...•..•....... 147
oil pumps, installing .........•...•..•....... 146
piston, installing ...........•...•..•....... 153
primary gear nut, installing ........•..•....... 150
rotor, installing .................•..•....... 153
shift drum locating unit, installing .........•.... 147
shift drum, installing ...................•.... 145
shift forks, installing ...................•.... 144
shift lever, installing ............•......•.... 158
shift rails, installing ............•......•.... 145
shift shaft, installing ............•......•.... 147
spark plug, installing ............•......•.... 158
starter idler gear, installing ................... 148
starter motor, installing ...................... 158
suction pump, installing ..................... 151
timing chain guide rail, installing ............... 153
timing chain securing guide, installing ............ 152
timing chain tensioning rail, installing ............ 152
timing chain, installing .................•.... 152
torque limiter, installing ................•.... 148
transmission shafts, installing .....•........... 144
valve clearance, adjusting ........•........... 157
valve cover, installing ...........•........... 158
water pump cover, installing ......•......•.... 151
Engin. di ••••• mbl'
alternator cover, removing .....•...•..•....... 106