400-660LC42003 REPAIR MANUAL REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN KTM Group Partner ART.NR.: 3.206.006-E 400-660LC4 REPAIR MANUAL 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 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS 13 14 15 16 IMPORTANT INFORMATION/UPDATING INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: 15-18, 20-28, 32, 35, 40-54, 64, 66-69, 73, 77, 79-81, 84-207, 219, 280-291, 314-319, 323, 378-387 Remove page (s) 2-1C to 2-3C 2-5C to 2-11C 3-3 4-1A 4-5 to 4-16 5-1A to 5-2A 5-12 5-14B to 5-17 5-21 / 5-25 6-1A to 6-2 6-5C to 6-19C 7-1 to 7-49C 8-1C to 8-37C 9-1 10-1.1C 11-1C 12-2C Replace by page (s) 2-1D to 2-3D 2-6D to 2-13D 3-3D 4-1D 4-5D to 4-17D 5-1D to 5-2D 5-12D 5-14D to 5-17D 5-21D / 5-25D 6-1D to 6-2D 6-5D to 6-21D 7-1D to 7-51D 8-1D to 8-49D 9-1D 10-2D 11-1D 12-2D 10-62D to 10-72D 11-22D to 11-27D 12-57D to 12-66D Insert page (s) 2-5D after page 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. ­ Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder. ­ Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. ­ Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading ,,Chapter 3". ­ Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents. EXPLANATION - UPDATING 3.205.49-E Repair Manual LC4 Basicversion Modelyear 1998 (Engine number with first digit ,,8") 6/1998 3.205.73-E Updating of Rep.Manual LC4 Modelyear 1999 (Engine number with first digit ,,9") 7/1999 3.205.89-E Art.-Nr. 3.206.006 -E Updating of Rep.Manual LC4 Modelyear 2000/2001 (Engine number with first digit ,,0" and ,,1") 9/2000 3.210.30-E Updating of Rep.Manual LC4 Modelljahr 2002 (Engine number with first digit ,,2") 12/2001 3.206.006-E Updating of Rep.Manual LC4 Modelljahr 2003 (Engine number with first digit ,,3") Modification / Updating: Special tools, hydraulic clutch, Keihin carburator, technical details model 2003, technical specification, Maintenance schedule and wiring diagrams for modell 2003 4/2003 Repair manual KTM LC4 Edition 4/2003 INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work. WARNING STRICT COMPLIANCE WITH THESE INSTRUCTIONS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. ! CAUTION ! IS NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC ! ,,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. KTM Austria's certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow. KTM Sportmotorcycle AG 5230 Mattighofen, Austria All design and assembly modification rights reserved. C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved 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 ­ whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. ­ please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349. ­ NOTE to table: Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E). You will find the number on the cover page or in the left margin on each right page of the manual. Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2. Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible. Enter the correct text in column 4. ­ ­ ­ Your corrections will be reviewed and incorporated in the next issue of our repair manual. Item no. of repair manual Page Current text Correct text Additional suggestions, requests or comments on our Repair Manuals (in German or English): Name mechanic/shop foreman Company/work shop 2-1D GENERAL INFORMATION INDEX 2 MODELS WITHOUT FRAME OIL CHANGING THE ENGINE OIL . . . . . CHANGING THE OIL FILTER . . . . . . CHANGING THE MICROFILTER . . . OIL CIRCUIT . . . . . . . . . . . . . . . . . OIL CIRCUIT 660 SMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 .2-2 .2-3 .2-4 .2-5 Art.-Nr. 3.206.006 -E MODELS WITH FRAME OIL CHANGING THE ENGINE OIL . . . . . . CHANGING THE FINE SCREEN FILTER CHANGING THE OIL FILTER . . . . . . . OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 .2-6 .2-7 .2-8 SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 EPC-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .2-13 Repair manual KTM LC4 2-2D up to Modell 2001 from Modell 2002 on Changing the engine oil (models without frame oil) NOTE: The engine oil change is to be carried out when the engine is still warm. WARNING AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT DO NOT BURN YOURSELF. 1 A A - ­ Place the motorbike on a horizontal surface. Remove the two plugs (1 and 2), and drain oil into a container. 2 1 2 NOTE: A third plug was installed in the 660 SMC model. Tightening torque: 20 Nm ! THE SCREW PLUG CAUTION ! A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. ­ Clean the plugs thoroughly with a fireproof solvent and compressed air, in order to remove the metal abrasion. ­ After all the oil has drained through, clean raised and flat faces and install plugs with seals. Tighten plug 1 with 30 Nm (22 ft.lb) and plug 2 with 20 Nm (15ft.lb). ­ Remove the oil dipstick at the clutch cover, pour in engine oil and replace the oil dipstick. Oil capacity (up to model 2002) : 1.40 l Oil capacity (from model 2003 on) : 1.50 l Changing the oil filter 5 Art.-Nr. 3.206.006 -E 3 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. ­ Remove banjo bolt 3 and the three bolts 4. ­ Remove oil filter cover 5 and oil filter. ­ Clean filter housing, oil filter cover and sealing surfaces. Check oil duct in oil filter cover if clogged. 4 ­ Press the new O-ring 6 into the groove of the filter cover (if necessary fix with grease). Mount a new oil filter 7 on the connection piece of the oil filter cover an mount the whole unit. NOTE: From model 2001 onwards the gasket 8 is mounted with a changed filter cover 5. If the new gasket 8 should be used on older engines, the filter cover must be flat regrinded or renewed (see Technical Info Nr. 0201/30/01). ­ Mount three bolts and tighten with 5 Nm (4 ft.lb). ­ Mount hollow bolt with seal rings and tighten with 15 Nm (11 ft.lb). 3 5 4 Repair manual KTM LC4 6 8 7 2-3D Changing the microfilter 1 2 Replace the microfilter while changing the engine oil. ­ To do so, remove bolts 1 and take off the microfilter cover 2. ­ Remove the microfilter, clean its parts and check the O-ring on the microfilter cover for signs of damage. ­ Insert a new microfilter into the filter housing, tilt the motorcycle sideways and fill the microfilter housing with engine oil. ­ Slightly grease the O-ring and mount the microfilter cover. Then put the motorcycle back on its stand. 1 3 ­ It is necessary to bleed the microfilter so that all lubricating points can be quickly supplied with engine oil. ­ To do this, fill with oil and remove the jet screw from the oil line on the clutch cover. ­ Start the engine and close off the bore on the clutch cover with a rag. ­ Allow the engine to run at idle until oil runs out of the oil line 3. ­ Turn off the engine. Mount the jet screw, using two new seal rings. ­ Torque the jet screw to 10 Nm and check for leaks. ­ Start the engine and let it idle for 1 - 2 minutes. ! DO CAUTION ! NOT REV UP THE ENGINE IMMEDIATELY AFTER AN OIL CHANGE ! KEEP IN MIND THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED WITH ENGINE OIL. JASO T903 MA TEMPERATURE 0°C 32°F 5W/40 10W/50 ­ Allow the engine to run until warm. Then, turn off the engine, and place the motorbike on a flat, level surface in an upright position (center stand). Wait for 5 minutes. Unscrew and remove the oil dipstick, and wipe it clean with a cloth. ­ Screw the dipstick in all the way and remove it again. The oil level should be between the two marks on the oil dipstick, however, it must never rise above the MAX mark. Otherwise, engine oil would get into the air filter box by way of the engine venting system. Add engine oil, if necessary. ­ Finally, check oil system and engine for leaks. ! ­ ONLY ­ ­ CAUTION ! USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS). INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE CRITERIA. NOTE: Dispose of used oil properly ! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter oil contaminates 1.000.000 liter water. O 87 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 2-4D 2-5D Oil circuit 660 SMCThe oil pump 1pumps the engine oil past the by-pass valve 2through the oil filter 3. After the oil filter, an oil lead branchesoff to a jet 4which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oilto the second jet 4and the microfilter 5, which filters out even the finest impurities. The cleaned engine oil is pumped throughthe oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6and drips into the crankcase. An additionaloil pump 7sucks the engine oil out of the crankcase and pumps it through the oil line 8to the gear wheels of the 4th and 5thgear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain 9runs through the oil sump and transports theengine oil upwards to the cylinder head. Through the bore bkthe oil reaches the camshaft bland the valves. 2-6D Changing the engine oil (models with frame oil) NOTE: For improved cooling of the engine oil, the front tube of the frame wa ...