KTM 400/620 LCA - Page 5

1.0
1.1
dek?
1.1.2
12
1.2.1
1.22
13
1.4
2.0
3.0
31
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.0
3.10
3.11
3.12
3.13
3.14
3.15
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
INDEX
GENERAL INFORMATIONS
Oil circuit - SX, Super Competition
Changing the engine oil - SX, Super Competition
Replacing the microfilter - SX, Super Competition
Oil circuit - EXC, EGS, Duke
Changing the engine oil - EXC, EGS, Duke
Changing the fine sreen filter - EXC, EGS, Duke
Changing oil filter
Special tools
REMOVING ENGINE
DISMANTLING THE ENGINE
Drain engine oil
Fitting crankshaft locking bolt
Timing train, Cylinder head
Cylinder
Piston
Chain sprocket
Oil line
Clutch, Primary Gear
Oil pump
Clutch release shaft
Flywheel
Parting of engine housing halves
Shifting mechanism
Transmission
Kickstarter
SERVICING ON INDIVIDUAL COMPONENTS
Left housing half
Right housing half
Crankshaft
Measurement/equalisation of crankshaft axial play
Piston
Mounting instructions for piston rings
Piston ring end gap
Measuring piston/cylinder
Nikasil coating of cylinder
Recoated Cylinder
Cylinder head
Cylinder head top section
Preassembly of cylinder head top section
Timing
Page
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4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
5.0
5.1
5.2
53
5.4
$3
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
STE
5.18
5.19
5.20
5.21
Auto Decompression
Automatic tensioner
Preassembly of automatic tensioner
Oil pump
Oil lines
Microfilter
Kickstarter
Preassembly of kickstarter shaft
Clutch EXC, EGS, Duke
Clutch SX, Super Comp.
Shifting mechanism
Preassembly of gear-change shaft
Shifting mechanism support
Gearbox
Assembly of main shaft
Assembly of take-off shaft
Waterpump
Checking the counter balancer shaft
Ignition
ENGINE ASSSEMBLY
Transmission, Shifting mechanism
Alignment of return spring
Pretensioning of the starter spring
Mounting crankshaft
Assembly of engine case
Mounting oil filter
Chain-sprocket
Mounting flywheel
Oil pump
Timing
Oil Pump Gear Wheel
Clutch
Counter balancer shaft primary pinion
Fitting clutch discs (EXC, EGS, Duke}
Fitting clutch discs (SX, Super Comp.}
Mounting release shaft
Adjustment of clutch disengagement
Piston and Cylinder
Microfilter (SX, Super Competition}
Cylinder head
Timing
43
44
44
44
45
45
46
46
48
49
50
50
51
51
52
53
54
54
55
46
57
60
60
60
61
oi
62
988
64
65
66
67
67
69
69
70
5.22 Water pump
5.23 Cylinder head top section
3.24 ‚Automatic tensioner
3.25 Adjustment of valve play
5.26 Function test auto decompression
5.27 Clutch cover
5.28 Ignition system
5.29 Adjustment of ignition point
5.30 Ignition Markings
X31 Marking the counterbalance shaft
532 Oil lines (SX, Super Competition}
5.33 Oil lines (EGS/ Duke)
6.0 REFITTING THE ENGINE
6.1 Installing the engine (SX, Super Comp.)
62 Installing the engine (EXC, ECS, Duke}
6.3 Engine oil
6.4 Replacing the microfilter (SX, Super Comp}
7.0 ELECTRICAL EQUIPMENT
ZI Checking voltage regulator - rectifier (Shindengen)
7.2 Checking voltage regulator - rectifier (ULO)
7.3 Checking the capacitor
74 Check voltage regulator
8.0 TROUBLE SHOOTING
9.0 TECHNICAL DATA - ENGINE
9.1 Technical data - engine
92 Tolerance, assembly clearance
93 Tightening Torques
10.0 LUBE- AND MAINTENANCE-SCHEDULE
11.0 WIRING DIAGRAMM
AU design and assembly modification rights reserved
72
72
73
73
73
74
75
75
75
76
76
76
78
78
78
80
80
81
81
él
82
86
93
93
93
97
100