User manual KTM 440-660 LC4 2003 - ENGINE REPAIR

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 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. If the oil system is not bled at all or bled insufficiently, the bearings of the engine will not get enough lubrication, which in turn may result in engine failure. 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. - up to Modell 2001 from Modell 2002 on 1 A A ­ Place the motorcycle on a horizontal surface. When working on a motorcycle with engine guard, remove the latter before commencing to change the engine oil. ­ Remove the two plugs 1 and 2, and drain oil into a container. ! PLUG A CAUTION ! MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. 2 1 2 Changing the fine screen filter 4 Art.-Nr. 3.206.006 -E Replace the fine screen 3 filter when changing the engine oil. ­ Loosen the three bolts and remove the cover. ­ Undo the spin-on filter 3 with the corresponding special tool, twist it off manually and let the engine oil out of the front pipe of the frame. ­ Unscrew plug 4 at the lower end of the front pipe and drain oil (up to model 2000). 3 6 5 ­ Clean sealing surfaces on the front pipe 5, fill new fine screen filter with engine oil, and oil rubber gasket 6. Replace fine screen filter and screw it back in place, your bare hand will do. ! USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. RESULT IN DAMAGE TO THE ENGINE! CAUTION USING ! ANOTHER FILTER BRAND CAN Repair manual KTM LC4 ­ From model 2001 onwards the drain plug 7 of the frame oil is located in the oil filter flange, draining is only possible after removing the oil filter. 7 ­ Clean all 3 plugs thoroughly with a fireproof solvent and compressed air, in order to remove the metal abrasion. ­ After all the oil has drained through, clean sealing areas and install plugs with gaskets. Tighten plug 1 with 30 Nm (23 ft.lb), plug 2 with 20 Nm and plug 4 with 10 Nm (up to model 2000). Drain plug of frame oil (model 2001 onwards) is to be mounted without a gasket and tightened to 10 Nm (7 lb.ft). 2-7D Changing the oil filter 3 1 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 1 and the three bolts 2. ­ Remove oil filter cover 3 and oil filter. ­ Clean filter housing, oil filter cover and sealing surfaces. Check oil duct in oil filter cover if clogged. 2 ­ Press the new O-ring 4 into the groove of the filter cover (if necessary fix with grease). Mount a new oil filter 5 on the connection piece of the oil filter cover an mount the whole unit. NOTE: From model 2001 onwards the gasket 6 is mounted with a changed filter cover 3. If the new gasket 6 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 banjo bolt with seal rings and tighten with 15 Nm (11 ft.lb). 1 3 2 4 6 5 ­ Remove the oil dipstick at the clutch cover, pour in engine oil and replace the oil dipstick. Oil quantity (engine only) : 1.40 liter ! IF CAUTION ! THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME, YOU MUST BLEED THE OIL SYSTEM! ­ Remove the plug 7 next to the steering head and use a lubricating syringe 8 (see special tools) to fill the front pipe with approx. 0.6 l engine oil. Add oil until it begins to emerge at bore B. ­ Mount the plug, using a new seal ring. ! DO CAUTION ! 7 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. B ­ 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. 8 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 ! 2-8D Oil circuit The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil line branches off to a jet 4 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 5, where the engine oil is cooled down. Afterwards the engine oil runs through the fine screen filter 6, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil line and the clutch cover into the crankshaft to the conrod bearing 7 and drips into the crankcase. An additional oil pump 8 sucks the engine oil out of the crankcase and pumps it through the oil line 9 to the gear wheels of the 4th and 5th gear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain bk runs through the oil sump and transports the engine oil upwards to the cylinder head. Through the bore hole bl the oil reaches the camshaft bm and the valves. 11 12 5 10 Art.-Nr. 3.206.006 -E Drain plug - frame oil up to Model 2000 7 4 6 8 3 1 Repair manual KTM LC4 2 Drain plug - frame oil Model 2001 onwards 9 2-9D Functional characteristics of the secondary air system (SLS) When the exhaust valve is open, the hot exhaust gases flow through the exhaust port 1 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). During these cyclic underpressure phases, the secondary air valve 2 opens, thus adding oxygen of the air to the hot exhaust gases through pipe 3. At higher engine speeds, the secondary air valve interrupts the oxygen supply to prevent overheating of the catalytic converter. Additionally, the secondary air valve prevents the exhaust gases from flowing back into the air filter box 4. When the motorcycle is pushed (high underpressure in the intake port) the control valve (ASV) 5 interrupts the air flow into the exhaust port to prevent exhaust detonations. The control valve is controlled via a control pipe 6. This control pipe transmits the underpressure from the intake port 7 to the control valve. During normal operation (slight underpressure in the intake port), the control valve is open. The reaction between the oxygen of the air and the harmful components of the exhaust gases (CO - carbon monoxide, HC hydrocarbon) reduces the content of harmful substances by approximately 50%. The use of a catalytic converter, in combination with the SLS, allows an additional significant reduction of pollutant emissions. 6 3 5 2 4 1 7 2-10D 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. The EPC control device opens the solenoid valve, directing an appropriate flow of fresh air onto the upper side of the slide membrane of the constant-pressure carburetor, thus reducing the opening speed of the slide. This mechanism significantly reduces the exhaust gas emissions of the vehicle. Art.-Nr. 3.206.006 -E SOLENOID VALVE Repair manual KTM LC4 2-11D SPECIAL TOOLS 6 26 11 12 20 1 16 23 64 8 39 ThreeBond 18 1215 Silicone Liquid Gasket Silicone Flüssige Dichtung 4# 4 5# 5 5 27 150 7 70 10 3 49 14 19 2 17 9 8 22 8# 15 48 65 130 35 2-12D FIG. 1 2 3 4 4# 5 5# 6 Repair manual KTM LC4 7 8 8# 9 10 11 12 14 15 16 16 17 18 19 19 20 22 23 26 39 48 49 PART NO. 560.12.001.000 583.29.003.000 580.12.005.025 584.29.009.000 580.12.009.000 510.12.016.000 584.29.031.000 580.12.015.089 580.12.015.095 580.12.015.100 580.12.015.101 585.29.015.102 590.29.021.044 580.12.019.000 590.29.019.000 6.276.470 590.29.041.000 6.899.785 584.29.059.000 590.29.034.000 151.12.017.000 151.12.018.000 151.12.018.100 584.29.012.000 3090.98 584.29.037.040 584.29.037.043 580.30.080.000 510.12.012.000 546.29.027.000 580.29.026.007 583.29.039.000 584.29.048.000 503.29.050.000 DESCRIPTION Universal engine work stand Clutch holder Mounting sleeve for crankshaft seal ring Ø 25 mm Magneto extractor (Kokusan) Magneto extractor (SEM) Protection cover for crankshaft (SEM) Protection cover for crankshaft (Kokusan) Piston ringspanner Ø 89 mm Piston ringspanner Ø 95 mm Piston ringspanner Ø 100 mm Piston ringspanner Ø 101 mm Piston ringspanner Ø 102 mm Extractor for primary gear and clutch hub Valve mounting set Valve mounting set Valve spring-push insert Feeler gauge for valve clearance Loctite 243 blue 6 ml Loctite 648 red 20 ml Wrench for mixture regulating screw Gear puller Internal bearing puller 12 - 16 mm Internal bearing puller 18 - 23 mm Flywheel holding spanner (Kokusan) Seal (Three-Bond) Mounting tool inner ring NJ207 (all versions of LC4) Mounting tool inner ring NJ306 (LC4-E) Crankshaft locking bolt Chain sprocket holder Clutch rivetting tool Limit plug gauge Ø 7,05 mm Oil filter wrench Syringe for pipe oil Bleeding syringe for hydraulic clutch Art.-Nr. 3.206.006 -E 2-13D 2 Checking the oil level of the hydraulic clutch 1 To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws 1 and cover 2 together with the rubber boot 3. The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (f.ex. Motorex Kupplungs-Fluid 75). ! ­ KTM ­ CAUTION ! USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID. 3 Bleeding of the hydraulic clutch 5 4 To bleed, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove screws 1 and take off cover 2 together with rubber bellows 3. At the slave cylinder of the clutch, remove the bleeder nipple 4. In its place, mount the bleeder syringe 5 which is filled with SAE 10 hydraulic oil. Refill oil until oil is discharged from the bore 6 of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer. 6 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. Motorex Kupplungs-Fluid 75). CAUTION ! ! ­ KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. ­ ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID. 3-1D REMOVING AND REFITTING ENGINE INDEX 3 REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 3-2D 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. ­ Disconnect the negative pole of the battery. ­ Undo the 2 hose clamps 1 as well as hose clamp 2. Pull the carburetor backwards out of the intake flange and swing it aside. 2 1 ­ Unhook the 4 springs 3 at the exhaust manifold. ­ Undo bolt 4. Art.-Nr. 3.206.006 -E 3 4 ­ Undo bolt 5 and remove the exhaust manifold. Repair manual KTM LC4 5 6 8 7 ­ Disconnect water hoses 6 and 7 from the water pump and let out the cooling liquid. ­ Remove the two bolts 8, disconnect and remove the fan. ­ Unhook the clutch cable and the decompression cable. ­ Disconnect the bleeder hose at the valve cover. 3-3D ­ Remove the two bolts 1 and take off the chain guard. ­ Remove the chain damping plate 6. ­ Remove the chain joint and take off the chain. 2 1 1 From model 2003 on: ­ Remove the 3 bolts 3 of the clutch slave cylinder and pull the clutch slave cylinder off the casing. 3 3 ­ Disconnect the bleeder hose 4. ­ Disconnect the positive cable 5 from the electric starter motor. 4 5 ­ Disconnect all electric plug and socket connections from the engine. ­ Remove the banjo bolt 6. 6 ­ Disconnect the water hose 7. 7 3-4D ­ Remove the jet screw 1. ­ Remove the left as well as the right engine retaining bracket 2. 2 1 ­ Remove bolt 3 as well as the swingarm pivot 4. ­ Then lift the engine out of the frame. 4 3 Installing the engine NOTE: To install the engine reverse the procedure indicated above. Art.-Nr. 3.206.006 -E ­ When working on a model with an engine guard keep in mind that opening A must be located on the right side and face the engine. Tightening torques: A Swingarm pivot: Engine mounting bolts M8: Engine mounting bolts M10: Banjo bolt (oil pipe on the frame): Jet screw (clutch cover): All other M6 bolts: All other M8 bolts: All other M10 bolts: 100 40 70 15 10 10 25 45 Nm Nm Nm Nm Nm Nm Nm Nm 74 30 50 11 7 7 19 33 ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb NOTE: Use only high-quality antifreeze (e.g. Shell Advance Coolant) for the cooling system. The frame oil should always be changed after engine repair. ! AFTER Repair manual KTM LC4 CAUTION ! INSTALLING THE ENGINE CAREFULLY BLEED THE OIL SYSTEM (SEE OIL CHANGE INSTRUCTIONS). DO NOT REV THE ENGINE DURING THE BLEEDING PROCESS ! ­ The motorcycle can be tested as soon as the engine is running smoothly. After the test run check and, if necessary, correct all liquid levels. 4-1D DISASSEMBLING THE ENGINE INDEX 4 DRAIN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 REMOVING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .4-2 REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES . . . . . . .4-3 REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 REMOVING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . .4-5 REMOVING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . .4-6 REMOVING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . . . .4-7 BLOCKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER . . . . . .4-8 REMOVING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 REMOVING CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 REMOVING ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . .4-11 REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 REMOVING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . . . .4-14 REMOVING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . .4-14 PARTING OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 REMOVING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 REMOVING THE TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . .4-17 REMOVING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 4-2D ­ Fit engine to engine work stand. ­ Remove bolt 1 together with the washers. Then remove the shift lever together with the V-seal ring behind. ­ Remove bolt 2 together with the washer. Then remove the kickstarter. 1 2 ­ Remove spark plug Art.-Nr. 3.206.006 -E up to model 2001 from modell 2002 on Drain engine oil ­ Remove oil drain plug 3 and magnetic plug 4 and drain oil. 3 Repair manual KTM LC4 4 3 4 Removing the electric starter motor ­ Undo 2 bolts 5 and remove the electric starter motor from the flange. 5 4-3D Removing the clutch release lever and the oil hoses ­ Undo bolt 1 and remove the clutch release lever. 1 ­ Remove the two banjo bolts 2 together with the seal rings and remove both oil hoses. 2 2 Removing the oil filter ­ Remove all three bolts 3 and take off the oil filter cover together with the O-ring or gasket. ­ Take the oil filter out of the engine housing. 3 Removing the EPC wiring harness 4 ­ Undo the 3 bolts 4 and remove the EPC wiring harness. 4 Removing the ignition (Kokusan 4K-2) ­ Undo 4 bolts and remove the ignition cover with the stator incl. gasket. 4-4D ­ Undo 6 bolts and remove starter flange incl. gasket. ­ Insert the holding spanner 2 into the 2 bores of the flywheel. ­ Hold the flywheel and remove the hexagon nut (LH thread). ­ Remove the disc. ! CAUTION ! 2 TO AVOID DISTORTION OF THE CRANK WEB, NEVER MOUNT THE CRANKSHAFT LOCKING BOLT TO STEADY THE FLYWHEEL. ­ Put the protection cover 1 onto the crankshaft and mount the flywheel extractor. Art.-Nr. 3.206.006 -E 1 ­ Pull off the flywheel and take the woodruff key out of the crankshaft. ! CAUTION ! NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID LOOSENING OF THE MAGNETS.