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F7375S4
KTM F7375S4 Manuals
Manuals and User Guides for KTM F7375S4. We have
2
KTM F7375S4 manuals available for free PDF download: Repair Manual, Setup Instructions
KTM F7375S4 Repair Manual (387 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 19.58 MB
Table of Contents
Table of Contents
4
1 Means of Representation 1
9
Symbols Used
9
Formats Used
9
2 Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
3 Important Notes 3
11
Manufacturer and Implied Warranty
11
Operating and Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
4 Serial Numbers
12
Chassis Number
12
Type Label
12
Engine Number
12
Fork Part Number
12
Shock Absorber Article Number
13
5 Motorcycle
14
Raising the Motorcycle with a Lift Stand
14
Removing the Motorcycle from the Lift Stand
14
Starting the Vehicle
14
Starting the Motorcycle to Check the Function
15
6 Fork, Triple Clamp
16
Adjusting the Compression Damping of the Fork
16
Adjusting the Rebound Damping of the Fork
17
Adjusting the Spring Preload of the Fork (All Six Days Models)
18
Bleeding the Fork Legs
18
Cleaning the Dust Boots of the Fork Legs
19
Removing the Fork Legs
19
Installing the Fork Legs
20
Removing the Fork Protector
21
Installing the Fork Protector
21
All Standard EXC/XC-W Models
22
Servicing the Fork
22
Disassembling the Fork Legs
22
Disassembling the Cartridge
25
Disassembling the Tap Compression
28
Checking the Fork Legs
29
Assembling the Tap Compression
30
Assembling the Cartridge
31
Assembling the Fork Legs
35
Lubricating the Steering Head Bearing
39
Removing the Lower Triple Clamp
39
Installing the Lower Triple Clamp
40
Changing the Steering Head Bearing
42
Checking the Play of the Steering Head Bearing
44
Adjusting the Steering Head Bearing Play
44
All Six Days Models
45
Servicing the Fork
45
Disassembling the Fork Legs
45
Disassembling the Cartridge
48
Disassembling the Tap Compression
51
Checking the Fork Legs
52
Assembling the Tap Compression
53
Assembling the Cartridge
54
Assembling the Fork Legs
58
Lubricating the Steering Head Bearing
63
Removing the Lower Triple Clamp
63
Installing the Lower Triple Clamp
64
Changing the Steering Head Bearing
66
Checking the Play of the Steering Head Bearing
67
Adjusting the Steering Head Bearing Play
68
7 Handlebar, Controls 7
69
Handlebar Position
69
Adjusting the Handlebar Position
69
Adjusting the Basic Position of the Clutch Lever
71
Checking the Rubber Grip
72
Checking Throttle Cable Routing
72
Checking the Play in the Throttle Cable
73
Adjusting the Play in the Throttle Cable
73
Setting the Characteristic Map of the Throttle Response
74
8 Frame
76
Checking the Frame
76
Removing the Engine Guard (All Six Days Models)
76
Installing the Engine Guard (All Six Days Models)
76
Changing the Footrests
76
9 Shock Absorber, Swingarm
80
Adjusting the High-Speed Compression Damping of the Shock Absorber
80
Adjusting the Low-Speed Compression Damping of the Shock Absorber
80
Adjusting the Rebound Damping of the Shock Absorber
81
Measuring the Rear Wheel Dimension Unloaded
82
Checking the Static Sag of the Shock Absorber
82
Checking the Riding Sag of the Shock Absorber
83
Adjusting the Spring Preload of the Shock Absorber
83
Adjusting the Riding Sag
84
Removing the Shock Absorber
85
Installing the Shock Absorber
85
Servicing the Shock Absorber
85
Removing the Spring
86
Disassembling the Damper
87
Disassembling the Seal Ring Retainer
88
Disassembling the Piston Rod
89
Replacing the Pilot Bushing
90
Checking the Damper
91
Removing the Heim Joint
92
Installing the Heim Joint
93
Assembling Seal Ring Retainer
93
Assembling the Piston Rod
94
Assembling the Damper
96
Bleeding and Filling the Damper
98
Filling Damper with Nitrogen
101
Installing the Spring
102
Checking the Swingarm
103
Checking the Heim Joint for Play
103
Changing the Heim Joint
104
Changing the Heim Joint on the Swingarm
105
Checking the Swingarm Bearing for Play
107
Removing the Swingarm
107
Installing the Swingarm
108
Changing the Swingarm Bearing
110
10 Exhaust 10
113
Removing the Manifold
113
Installing the Manifold
114
Removing the Main Silencer
115
Installing the Main Silencer
116
Changing the Glass Fiber Yarn Filling in the Main Silencer
116
11 Air Filter
118
Air Filter
118
Removing the Air Filter Box Cover
118
Installing the Air Filter Box Cover
118
Removing the Air Filter
119
Installing the Air Filter
119
Cleaning the Air Filter and Air Filter Box
120
Preparing Air Filter Box Cover for Securing
120
Sealing the Air Filter Box
121
12 Fuel Tank, Seat, Trim
122
Opening the Filler Cap
122
Closing the Filler Cap
122
Removing the Seat
123
Mounting the Seat
123
Removing the Fuel Tank
124
Installing the Fuel Tank
125
Changing the Fuel Screen
127
Changing the Fuel Filter
128
Changing the Fuel Pump
131
Checking the Fuel Pressure
134
13 Mask, Fender
136
Removing Front Fender
136
Installing Front Fender
136
Removing the Headlight Mask with the Headlight
137
Installing the Headlight Mask with the Headlight
137
14 Wheels 14
139
Checking the Tire Air Pressure
139
Checking the Tire Condition
139
Checking the Wheel Bearing for Play
140
Checking the Brake Discs
141
Checking the Rim Run-Out
141
Checking Spoke Tension
142
Front Wheel
143
Removing the Front Wheel
143
Installing the Front Wheel
144
Changing the Front Brake Disc
144
Changing Front Wheel Bearing
145
Rear Wheel
146
Removing the Rear Wheel
146
Installing the Rear Wheel
147
Changing the Rear Brake Disc
148
Changing the Rear Wheel Bearing
149
Checking the Chain for Dirt
151
Cleaning the Chain
151
Checking the Chain Tension
152
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
153
Adjusting the Chain Tension
155
Changing the Drivetrain Kit
156
15 Wiring Harness, Battery 15
159
Ignition Curve Plug-In Connector
159
Changing the Main Fuse
159
Changing the Fuses of Individual Power Consumers
161
Disconnecting the Negative Cable of the Battery
162
Connecting the Negative Cable of the Battery
163
Removing the Battery
163
Installing the Battery
164
Recharging the Battery
165
Checking the Charging Voltage
166
Checking the Open-Circuit Current
167
Checking the Starter Relay
167
Diagnostics Connector
168
16 Brake System 16
169
Checking the Front Brake Linings
169
Changing the Front Brake Linings
169
Checking the Free Travel of the Hand Brake Lever
171
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
172
Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)
172
Checking the Front Brake Fluid Level
172
Adding Front Brake Fluid
173
Changing the Front Brake Fluid
174
Checking the Brake Linings of the Rear Brake
176
Changing the Rear Brake Linings
176
Checking the Free Travel of Foot Brake Lever
178
Adjusting the Basic Position of the Foot Brake Lever
179
Checking the Rear Brake Fluid Level
180
Adding Rear Brake Fluid
180
Changing the Rear Brake Fluid
181
17 Lighting System, Instruments
184
Changing the Headlight Bulb
184
Changing the Turn Signal Bulb (All EXC Models)
184
Checking the Headlight Setting
185
Adjusting the Headlight Range
186
Changing the Combination Instrument
186
Combination Instrument Overview
187
Activation and Test
187
Setting the Kilometers or Miles
187
Adjusting the Combination Instrument Function
188
Setting the Clock
189
Activating Additional Functions
189
Setting the Wheel Circumference
190
Viewing the Lap Time
190
18 Engine
192
Cleaning the Pressure Sensor Hose
192
Removing the Engine
192
Installing the Engine
198
Engine Disassembly
205
Clamping the Engine into the Engine Work Stand
205
Removing the Shift Lever
205
Removing the Clutch Push Rod
205
Draining the Gear Oil
205
Removing the Spacer
206
Removing the Alternator Cover
206
Removing the Kick Starter
207
Removing Injection Valves
207
Removing the Cylinder Head
207
Removing the Cylinder
208
Removing the Piston
210
Removing the Water Pump Cover
211
Removing the Clutch Cover
211
Removing the Clutch Discs
212
Removing the Clutch Basket
213
Removing the Balancer Shaft
214
Removing the Kick Starter Shaft
215
Removing the Intermediate Kick Starter Gear
215
Removing the Shift Shaft
216
Removing the Shift Drum Locating Unit
216
Removing the Locking Lever
216
Removing the Rotor
216
Removing the Starter Motor
217
Removing the Reed Valve Housing
218
Removing the Left Engine Case Section
219
Removing the Shift Rails
219
Removing the Shift Drum
219
Removing the Shift Forks
220
Removing the Transmission Shafts
220
Removing the Crankshaft
220
Working on Individual Parts
221
Working on the Right Section of the Engine Case
221
Working on the Left Section of the Engine Case
222
Removing the Crankshaft Bearing Inner Race
224
Installing the Crankshaft Bearing Inner Race
224
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
225
Checking the Crankshaft Run-Out at the Bearing Pin
226
Checking/Measuring the Cylinder
226
Cleaning the Pressure Sensor Cylinder Connection
227
Removing the Exhaust Control
227
Checking the Exhaust Control
229
Installing the Exhaust Control
231
Cylinder - Nikasil Coating
234
Checking/Measuring the Piston
234
Checking the Piston Ring End Gap
235
Measuring the Piston/Cylinder Mounting Clearance
235
Disassemble the Reed Valve Housing
236
Checking the Reed Valve Housing, Reed Valve and Intake Flange
237
Assemble the Reed Valve Housing
237
Working on the Clutch Cover
239
Checking the Clutch
242
Preassembling Shift Shaft
243
Checking the Shift Mechanism
244
Disassembling the Main Shaft
245
Disassembling the Countershaft
246
Checking the Transmission
246
Assembling the Main Shaft
248
Assembling the Countershaft
248
Checking the Kick Starter
250
Preassembling the Kick Starter Shaft
250
Checking the Electric Starter Drive
251
Engine Assembly
252
Installing the Crankshaft
252
Installing the Transmission Shafts
253
Installing the Shift Forks
253
Installing the Shift Drum
254
Installing the Shift Rails
254
Installing the Left Engine Case Section
254
Installing the Reed Valve Housing
255
Installing the Starter Motor
256
Installing the Rotor
257
Installing the Locking Lever
257
Installing the Shift Drum Locating Unit
258
Installing the Shift Shaft
258
Installing the Intermediate Kick Starter Gear
258
Installing the Kick Starter Shaft
258
Installing the Balancer Shaft
259
Installing the Clutch Basket
260
Installing the Clutch Discs
261
Installing the Clutch Cover
263
Installing the Water Pump Cover
265
Installing the Piston
266
Installing the Cylinder
267
Checking the X-Distance
269
Adjusting the X-Distance
269
Adjusting the Z-Distance
271
Installing the Cylinder Head
273
Installing Injection Valves
274
Installing the Kick Starter
274
Installing the Alternator Cover
274
Installing the Spacer
275
Installing the Gear Oil Drain Plug
275
Installing the Clutch Push Rod
276
Installing the Shift Lever
276
Removing the Engine from the Engine Work Stand
276
19 Clutch 19
277
Checking/Correcting the Fluid Level of the Hydraulic Clutch
277
Changing the Hydraulic Clutch Fluid
278
Checking the Clutch
279
20 Water Pump, Cooling System
288
Cooling System
288
Checking the Antifreeze and Coolant Level
288
Checking the Coolant Level
289
Draining the Coolant
289
Refilling with Coolant
290
21 Exhaust Control 21
293
Checking/Adjusting the Exhaust Control
293
22 Lubrication System
296
Changing the Gear Oil
296
Checking the Gear Oil Level
297
Adding Gear Oil
297
Checking 2-Stroke Oil Level
298
Opening 2-Stroke Oil Tank Cap
299
Adding 2-Stroke Oil
299
Closing 2-Stroke Oil Tank Cap
299
Priming the Oil Pump
300
Replacing the Oil Pump
301
23 Ignition System
304
Checking the Ignition System
304
Ignition Coil - Checking the Primary Winding
305
Checking the Spark Plug Connector
306
Alternator - Checking the Stator Winding
306
Checking the Crankshaft Position Sensor
307
Changing the Spark Plug
308
Changing the Spark Plug and Spark Plug Connector
309
Removing the Stator
309
Installing the Stator
310
24 Electric Starter 24
311
Checking the Starter Motor
311
25 Throttle Valve Body
312
Adjusting the Idle Speed
312
Programming Ambient Pressure
312
Cold Start Button
313
26 Technical Data
314
Engine
314
All 250 Models
314
All 300 Models
314
Tolerance, Engine Wear Limits
315
Engine Tightening Torques
316
Capacities
317
Gear Oil
317
Engine Oil
317
Coolant
317
Fuel
318
Chassis
318
Electrical System
319
Tires
319
Fork
319
All Standard EXC/XC-W Models
319
All Six Days Models
320
Shock Absorber
320
Chassis Tightening Torques
321
27 Cleaning, Care
324
Cleaning, Care
324
Cleaning the Motorcycle
324
Checks and Maintenance Steps for Winter Operation
325
28 Storage
326
Preparing for Use after Storage
327
29 Service Schedule
328
Additional Information
328
Required Work
328
Recommended Work
329
30 Wiring Diagram
332
All EXC Models)
332
All EXC Models)
334
All EXC Models)
336
All EXC Models)
338
All EXC Models)
340
All EXC Models)
342
All EXC Models)
344
All EXC Models)
346
All XC-W Models)
348
All XC-W Models)
350
All XC-W Models)
352
All XC-W Models)
354
All XC-W Models)
356
All XC-W Models)
358
31 Substances
360
32 Auxiliary Substances
362
33 Special Tools
364
34 Standards 34
379
35 Index of Special Terms
380
36 List of Abbreviations 36
381
Index
382
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KTM F7375S4 Setup Instructions (45 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 2.76 MB
Table of Contents
Means of Representation
4
Mount and Tighten Screws
7
Remove Screws
21
Mount and Tighten Screw
24
Tighten Screws 3 . Guideline
28
Adding 2-Stroke Oil
35
Setting the Clock
39
Technical Data
40
Auxiliary Substances
43
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