KTM 400 EXC EU Repair Manual page 6

CONTENTS
Removing the crankshaft seal ring in the clutch cover ..... 118
Fitting the crankshaft seal ring into the clutch cover ....... 118
Removing the water pump ............................................ 119
Installing the water pump............................................. 119
Checking the balancer shaft ......................................... 120
Removing the timing chain sprocket.............................. 120
Installing the timing chain sprocket............................... 121
Changing the connecting rod, conrod bearing and crank
pin............................................................................. 121
Checking crankshaft run-out at bearing pin .................... 123
cylinder - Nikasil ® coating ............................................ 123
Checking/measuring cylinder ........................................ 123
Checking/measuring the piston ..................................... 124
Checking the piston ring end gap .................................. 124
Piston/cylinder - determining the mounting clearance ..... 125
Checking the oil pumps for wear ................................... 125
Disassembling the autodecompressor ............................ 125
Assembling the autodecompressor................................. 126
Checking camshaft ...................................................... 126
Checking the timing assembly ...................................... 127
Preparing the timing chain tensioner for installation ....... 127
Removing the rocker arm.............................................. 128
Removing the valves .................................................... 128
Changing camshaft bearing .......................................... 129
Checking valves........................................................... 129
Checking valve springs ................................................. 130
Checking valve spring seat............................................ 130
Checking the cylinder head .......................................... 130
Checking the rocker arm shafts ..................................... 131
Installing valves .......................................................... 131
Installing the rocker arm .............................................. 132
Checking clutch .......................................................... 132
Checking shift mechanism ........................................... 133
Preassembling the shift shaft........................................ 134
Dismantling the main shaft .......................................... 134
Assembling the main shaft ........................................... 135
Dismantling the countershaft........................................ 135
Assembling the countershaft......................................... 136
Checking the transmission............................................ 136
Premounting the kickstarter shaft.................................. 137
Checking the electric starter mode ................................ 138
Removing the freewheel ............................................... 139
Checking the freewheel ................................................ 139
Installing the free-wheel............................................... 139
30/ENGINE ASSEMBLY ................................................... 141
Installing the crankshaft............................................... 141
Installing the transmission shaft ................................... 141
Installing the shift forks ............................................... 141
Installing the shift drum............................................... 142
Installing the shift rails ................................................ 142
Installing the left engine case ....................................... 142
Installing the free wheel gear........................................ 143
Installing the primary gear............................................ 143
Installing the oil pumps ............................................... 143
Installing the oil pump gears ........................................ 144
Installing the locking lever............................................ 144
Installing the shift drum locating .................................. 144
Installing the shift shaft ............................................... 144
Installing the kickstarter idler gear ................................ 145
Installing the kickstarter shaft ...................................... 145
Installing the starter idler gear ...................................... 145
Installing the torque limiter .......................................... 145
Installing the balancer shaft ......................................... 146
Installing the outer clutch hub...................................... 146
Installing the primary gear nut ...................................... 147
Installing the clutch discs ............................................ 147
Installing the clutch cover ............................................ 147
Installing the water pump cover .................................... 148
Installing the kickstarter............................................... 148
Installing the suction pump .......................................... 148
Installing the ignition pulse generator............................ 149
Installing the timing chain............................................ 149
Installing the timing chain securing guide...................... 149
Installing the timing chain tensioning rail ...................... 149
Installing the timing chain guide rail ............................. 150
Installing the balance weight ........................................ 150
Installing the rotor ....................................................... 150
Installing the piston..................................................... 150
Installing the cylinder head .......................................... 152
Installing the camshaft ................................................ 153
Installing the timing chain tensioner ............................. 153
Checking the valve clearance ........................................ 154
Adjusting the valve clearance........................................ 154
Installing the generator cover........................................ 154
Installing the shift lever ............................................... 155
Installing the valve cover .............................................. 155
Installing the spark plug............................................... 155
Installing the starter motor ........................................... 155
Mounting oil filter........................................................ 156
Filling up with engine oil.............................................. 156
Filling up with gear oil ................................................. 156
Removing the engine from the work stand...................... 157
31/CARBURETOR ........................................................... 158
Choke (EXC AUS, XC‑W, EXC USA) ............................... 158
Choke (EXC EU, EXC SIX DAYS) ................................... 158
Removing the carburetor .............................................. 158
Disassembling the carburetor........................................ 159
Checking/adjusting the carburetor components............... 161
Checking/adjusting the accelerator pump....................... 162
Checking the choke slide.............................................. 162
Checking the jet needle................................................ 162
Checking the throttle slide............................................ 163
Checking the needle jet................................................ 163
Checking the float needle valve..................................... 163
Checking/adjusting the float level.................................. 164
Checking/setting the throttle slide opening..................... 164
Checking the throttle valve sensor ................................. 164
Adjusting the position of the throttle position sensor ....... 165
Assembling the carburetor ............................................ 166
Installing the carburetor ............................................... 168
Carburetor - adjusting idle ............................................ 169
Emptying the carburetor float chamber .......................... 170
32/CLUTCH .................................................................... 172
Checking fluid level of hydraulic clutch ......................... 172
Changing the hydraulic clutch fluid ............................... 172
33/TRANSMISSION......................................................... 174
Removing the engine sprocket ...................................... 174
Installing the engine sprocket ....................................... 174
35/WATER PUMP, COOLING SYSTEM .............................. 175
Cooling system ............................................................ 175
Checking the antifreeze and coolant level ...................... 175
Checking the coolant level............................................ 176
Draining coolant .......................................................... 176
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