KTM400660LC42003

REPAIRMANUALREPARATURANLEITUNGMANUALEDIRIPARAZIONEMANUELDERÉPARATIONMANUALDEREPARACIÓNART.NR.:3.206.006-EKTMGroupPartner400-660LC42003400-660LC4REPAIRMANUAL1SERVICE-INFORMATIONS2GENERALINFORMATION3REMOVINGANDREFITTINGENGINE4DISASSEMBLINGTHEENGINE5SERVICINGONINDIVIDUALCOMPONENTS6ASSEMBLINGTHEENGINE7ELECTRICAL8FUELSYSTEM9TROUBLESHOOTING10TECHNICALSPECIFICATIONS11PERIODICMAINTENANCESCHEDULE12WIRINGDIAGRAMS13141516Removepage(s)Replacebypage(s)Insertpage(s)afterpage2-1Cto2-3C2-1Dto2-3D2-5D2-5Cto2-11C2-6Dto2-13D3-33-3D4-1A4-1D4-5to4-164-5Dto4-17D5-1Ato5-2A5-1Dto5-2D5-125-12D5-14Bto5-175-14Dto5-17D5-21/5-255-21D/5-25D6-1Ato6-26-1Dto6-2D6-5Cto6-19C6-5Dto6-21D7-1to7-49C7-1Dto7-51D8-1Cto8-37C8-1Dto8-49D9-19-1D10-1.1C10-2D10-62Dto10-72D11-1C11-1D11-22Dto11-27D12-2C12-2D12-57Dto12-66DIMPORTANTINFORMATION/UPDATINGINSTRUCTIONSTobeabletocontinueusingtheexistingloose-leafrepairinstructions,simplyprintthefollowingpagesandinsertthemintheexistingrepairinstructions:15-18,20-28,32,35,40-54,64,66-69,73,77,79-81,84-207,219,280-291,314-319,323,378-387KTMREPAIRMANUALINLOOSE-LEAFFORMSTORINGTHEREPAIRMANUALINTHEBINDER–Puttheindexintothebinder.–Putthefrontpageoftherepairmanual(210x297mm)intothetransparentpocketprovidedforthispurposeontheoutsideofthebinder.–Putthespinelabel(170x45mm)intothetransparentpocketprovidedforthispurposeonthespineofthebinder.–Putthesummarylistofcontents(150x297mm)intothetransparentpocketprovidedforthispurposeontheinsideofthebinderorinsertthispageonthebeginningofthemanual.–Theninserttheindividualchaptersofthemanualbetweenthesheetsoftheindexaccordingtothepagenumberprintedintherightbottomcornerofeachpage.Example:pageno.3-53=chapter35=page5Allpageswithapagenumberthatbeginswiththedigit3,forexample,mustbeputundertheindexheading„Chapter3“.–Indexsheetsthathavenotbeenmarkedwithacertainchapterareforyourpersonalconvenience.Therespectiveheadingscanbeenteredinthelistofcontents.RepairmanualKTMLC4Art.-Nr.3.206.006-EEXPLANATION-UPDATINGEdition4/20033.205.49-ERepairManualLC46/1998BasicversionModelyear1998(Enginenumberwithfirstdigit„8“)3.205.73-EUpdatingofRep.ManualLC47/1999Modelyear1999(Enginenumberwithfirstdigit„9“)3.205.89-EUpdatingofRep.ManualLC49/2000Modelyear2000/2001(Enginenumberwithfirstdigit„0“and„1“)3.210.30-EUpdatingofRep.ManualLC412/2001Modelljahr2002(Enginenumberwithfirstdigit„2“)3.206.006-EUpdatingofRep.ManualLC44/2003Modelljahr2003(Enginenumberwithfirstdigit„3“)Modification/Updating:Specialtools,hydraulicclutch,Keihincarburator,technicaldetailsmodel2003,technicalspecification,Maintenancescheduleandwiringdiagramsformodell2003INTRODUCTIONThisrepairmanualoffersextensivrepair-instructionsandisanup-to-dateversionthatdescribesthelatestmodelsoftheseries.However,therighttomodificationsintheinterestoftechnicalimprovementisreservedwithoutupdatingthecurrentissueofthismanual.Adescriptionofgeneralworkingmodescommoninworkshopshasnotbeenincluded.Safetyrulescommonintheworkshophavealsonotbeenlisted.Wetakeitforgrantedthattherepairsaremadebyqualifiedprofesionallytrainedmechanics.Readthroughtherepairmanualbeforebeginningwiththerepairwork.
WARNING
STRICTCOMPLIANCEWITHTHESEINSTRUCTIONSISESSENTIALTOAVOIDDANGERTOLIFEANDLIMB.!CAUTION!NON-COMPLIANCEWITHTHESEINSTRUCTIONSCANLEADTODAMAGEOFMOTORCYCLECOMPONENTSORRENDERMOTORCYCLESUNFITFORTRAFFIC!„NOTE”POINTSOUTUSEFULTIPS.UseonlyORIGINALKTMSPAREPARTSwhenreplacingparts.TheKTMhighperformanceengineisonlyabletomeetuserexpectationsifthemaintenanceworkisperformedregularlyandprofessionally.KTMAustria’scertificateofachievementforitsqualitysystemISO9001isthebeginningofanongoingtotalreengineeredqualityplanforabrightertomorrow.KTMSportmotorcycleAG5230Mattighofen,AustriaAlldesignandassemblymodificationrightsreserved.CbyKTMSPORTMOTORCYCLEAG,AUSTRIAAllrightsreservedREPLYFAXFORREPAIRMANUALSWehavemadeeveryefforttomakeourrepairmanualsasaccurateaspossiblebutitisalwayspossibleforamistakeortwotocreepin.Tokeepimprovingthequalityofourrepairmanuals,werequestmechanicsandshopforementoassistusasfollows:Ifyoufindanyerrorsorinaccuraciesinoneofourrepairmanual–whetherthesearetechnicalerrors,incorrectorunclearrepairprocedures,toolproblems,missingtechnicaldataortorques,inaccurateorincorrecttranslationsorwording,etc.–pleaseentertheerror(s)inthetablebelowandfaxthecompletedformtousat0043/7742/6000/5349.NOTEtotable:–Enterthecompleteitemno.fortherepairmanualincolumn1(e.g.:3.210.66-E).Youwillfindthenumberonthecoverpageorintheleftmarginoneachrightpageofthemanual.–Enterthecorrespondingpagenumberintherepairmanual(e.g.:5-7c)incolumn2.–Enterthecurrenttext(inaccurateorincomplete)incolumn3byquotingordescribingtherespectivepassageofthetext.Ifyourtextdeviatesfromthetextcontainedintherepairmanual,pleasewriteyourtextinGermanorEnglishifpossible.–Enterthecorrecttextincolumn4.Yourcorrectionswillbereviewedandincorporatedinthenextissueofourrepairmanual.Itemno.ofrepairmanualPageCurrenttextCorrecttextAdditionalsuggestions,requestsorcommentsonourRepairManuals(inGermanorEnglish):Namemechanic/shopforemanCompany/workshopMODELSWITHOUTFRAMEOILCHANGINGTHEENGI