KTM  400 – 660 LC4 SERVICE REPAIR MANUAL 1998 1999 2000 2001 2002 2003

KTM  400 – 660 LC4 SERVICE REPAIR MANUAL 1998 1999 2000 2001 2002 2003

 

Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your motorbike. Read and print pages or copy the entire manual to your hard drive. 

387 PAGES

 

 

TABLE OF CONTENTS:

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 Owner’s Manuals

 

MANUALS COVER:

MODELS WITHOUT FRAME OIL

CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

CHANGING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

CHANGING THE MICROFILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

OIL CIRCUIT 660 SMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

MODELS WITH FRAME OIL

CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

CHANGING THE FINE SCREEN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

CHANGING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

EPC-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .2-13

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

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

WORKING ON THE RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . .5-3

WORKING ON THE LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . .5-5

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY . . . . . . . . .5-7

CHECKING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

MOUNTING INSTRUCTIONS FOR PISTON RINGS . . . . . . . . . . . . . . . . . . .5-8

PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

MEASURING PISTON AND CYLINDER, DETERMINING

THE PISTON FITTING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

CYLINDER – NIKASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

DISASSEMBLING THE CYLINDER HEAD AND CHECKING

THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND

CHECKING COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . .5-11

PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . .5-11

CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR . . .5-12

DISASSEMBLING THE CAMSHAFT AND CHECKING THE

COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

PRE-ASSEMBLING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

PREASSEMBLY OF AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . .5-13

DISASSEMBLING THE OIL PUMPS AND CHECKING THE

COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

OIL LINES (SX, SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

OIL LINES (SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

OIL LINES (660 SMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

OIL LINES (MODELS WITH FRAME OIL) . . . . . . . . . . . . . . . . . . . . . . . . .5-15

CHECKING THE KICKSTARTER COMPONENTS FOR WEAR . . . . . . . . . . .5-16

PREASSEMBLY OF KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .5-16

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB . . . .5-16

CHECKING THE CLUTCH COMPONENTS FOR WEAR . . . . . . . . . . . .5-17

CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR . . . .5-18

PREASSEMBLY OF SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

SHIFT MECHANISM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

DISASSEMBLING AND REASSEMBLING THE WATER PUMP . . . . . . . .5-19

IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION . . . . .5-20

ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

ASSEMBLING THE COUNTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . .5-21

REMOVING THE INTERMEDIATE GEAR . . . . . . . . . . . . . . . . . . . . . .5-22

CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

REPLACING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . .5-22

ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2) . . .5-23

REPLACING THE STATOR (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . .5-23

IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

CHECKING THE STATOR (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

REPLACING THE STATOR (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

CHECKING THE STATOR (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . .5-25

REPLACING THE STATOR (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . .5-25

MOUNTING THE KICKSTARTER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

MOUNTING TRANSMISSION AND SHIFT MECHANISM . . . . . . . . . . . . . .6-2

ADJUSTMENT OF RETURN SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

PRETENSIONING OF THE STARTER SPRING . . . . . . . . . . . . . . . . . . . . . . .6-4

MOUNTING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

ASSEMBLY OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

MOUNTING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

MOUNTING THE ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

MOUNTING THE TIMING GEAR AND THE TIMING CHAIN . . . . . . . . . . . .6-7

MOUNTING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

MOUNTING THE BALANCER SHAFT AND THE PRIMARY PINION . . . . . . .6-8

MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

MOUNTING THE CLUTCH DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

INSTALLING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . . .6-9

ADJUSTING THE CLUTCH RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

MEASURE DIMENSION „Y“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

MOUNTING PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

MOUNTING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

MOUNTING THE CAMSHAFT, TIMING MARKS . . . . . . . . . . . . . . . . . . . .6-12

MOUNTING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

MOUNTING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . .6-14

MOUNTING THE AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . .6-14

AUTOMATIC DECOMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . .6-14

ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

MOUNTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

MOUNTING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . .6-16

MOUNTING THE IGNITION (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . .6-16

ADJUSTING THE PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

MOUNTING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

ADJUSTMENT OF IGNITION POINT (SEM) . . . . . . . . . . . . . . . . . . . . . . .6-18

MOUNTING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . .6-18

MOUNTING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . .6-19

ADJUSTMENT OF IGNITION POINT (KOKUSAN 4K-3) . . . . . . . . . . . . . .6-19

MOUNTING THE OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

MOUNTING THE CLUTCH RELEASE LEVER . . . . . . . . . . . . . . . . . . . . . . .6-20

MOUNTING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . .6-20

MOUNTING THE WATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

POURING IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

MOUNTING THE KICKSTARTER AND THE SHIFT LEVER . . . . . . . . . . . . .6-21

ELECTRICAL – SUPER COMPETITION . . . . . . . . . . . . . . . . . . . . . . . . .7-4

CHECKING THE VOLTAGE REGULATOR-RECTIFIER . . . . . . . . . . . . . . . . . .7-4

CHECKING THE VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

ELECTRICAL – LC4 COMPETITION . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . . .7-6

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

CHECKING THE NEUTRAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

ELECTRICAL – LC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . . .7-9

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-12

CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . .7-12

CHECKING THE DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-13

CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-14

TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-14

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-16

EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

DISMOUNT / RENEW SOLENOID VALVE FOR EPC . . . . . . . . . . . . . . . . .7-18

CHECK OF SOLENOID VALVE FOR EPC . . . . . . . . . . . . . . . . . . . . . . . . .7-18

CONTROLLER OF THE EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

CHECK OF EPC SYSTEM MICROSWITCH . . . . . . . . . . . . . . . . . . . . . . . .7-19

REPLACING THE EPC SYSTEM MICROSWITCH . . . . . . . . . . . . . . . . . . . .7-19

CHECK OF IDLE SWITCH / CONTACT SCREWS . . . . . . . . . . . . . . . . . . .7-19

ELECTRICAL – DUKE-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . .7-21

REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-24

CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-24

CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-26

TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-26

IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29

TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-29

ELECTRICAL – SXC ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30

CHECKING THE VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .7-30

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30

ELECTRICAL – SC ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

CHECKING THE VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .7-31

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

ELECTRICAL – DUKE ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . .7-33

REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34

ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35

CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-36

CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-36

CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37

CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37

CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-37

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-38

TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-38

CHECKING THE IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39

CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41

TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-41

MEASUREMENTS WITH PEAK VOLTAGE ADAPTER

(FROM MODEL 2000 ON)

DYNAMIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE . . .7-42

STATIC IGNITION VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE . . .7-43

STATIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE . . .7-45

STATIC IGNITION VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . . . . . . .7-47

STATIC GENERATOR VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . . . . .7-49

CHECKING SPEEDOMETER AND SPEEDOMETER SENSOR . . . . . . . . . . . .7-51

MIKUNI BST 40

PART-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

FULL-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

CHECKING/ADJUSTING THE THROTTLE SENSOR . . . . . . . . . . . . . . . . . . .8-9

ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

CHECK FLOAT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

DELL’ORTO

DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . .8-12

ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . . . . .8-13

DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . .8-16

ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . . . . .8-18

DISASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . .8-21

ASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . . . .8-22

CHECK FLOAT LEVEL (DELL’ORTO 38 ND / 40 SD) . . . . . . . . . . . . . . . . .8-25

CHECKING AXIAL CLEARANCE OF FLOAT (DELL’ORTO 38 ND / 40 SD) . .8-25

ADJUST HOT START DEVICE (DELL’ORTO 40 SD) . . . . . . . . . . . . . . . . . .8-25

ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26

ADJUSTING THE CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26

KEIHIN FCR 41

DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28

CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-32

ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-35

CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-36

DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-36

ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37

CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-38

KEIHIN FCR-MX 41

DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40

CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44

ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-47

CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-48

DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-48

ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49

CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-49

TROUBLE SHOOTING (SX, SXC, SC, SMC) . . . . . . . . . . . . . . . . . . . .9-2

TROUBLE SHOOTING (LC4 COMPETITION) . . . . . . . . . . . . . . . . . . .9-4

TROUBLE SHOOTING (LC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7

 

TECHNICAL SPECIFICATIONS:

MODEL 1998

TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC . . . . . . . . . . . . . .10-3

TECHNICAL SPECIFICATIONS – CHASSIS 400/540 SXC . . . . . . . . . . . . . .10-5

TECHNICAL SPECIFICATIONS – ENGINE 400/620 SX, SC . . . . . . . . . . . . .10-6

TECHNICAL SPECIFICATIONS – CHASSIS 400/620 SX, SC . . . . . . . . . . . .10-8

TECHNICAL SPECIFICATIONS – ENGINE 620 LC4 COMPETITION . . . . . .10-9

TECHNICAL SPECIFICATIONS – CHASSIS 620 LC4 COMPETITION . . . . .10-11

TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC . . . . . . . . . . . . . .10-12

TECHNICAL SPECIFICATIONS – CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-15

TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE-R . . . . . . . .10-16

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE-E . . . . . . . . . . . . . .10-17

 

MODEL 1999

TECHNICAL SPECIFICATIONS – ENGINE 400/540 SXC, 620 SX . . . . . . . 10-18

TECHNICAL SPECIFICATIONS – CHASSIS 400/540 SXC, 620 SX . . . . . . 10-20

TECHNICAL SPECIFICATIONS – ENGINE 400/620 SC . . . . . . . . . . . . . . 10-21

TECHNICAL SPECIFICATIONS – CHASSIS 400/620 SC . . . . . . . . . . . . . 10-23

TECHNICAL SPECIFICATIONS – ENGINE 620 LC4 COMPETITION . . . . . 10-24

TECHNICAL SPECIFICATIONS – CHASSIS 620 LC4 COMPETITION . . . . 10-26

TECHNICAL SPECIFICATIONS – ENGINE 400/640 LC4 . . . . . . . . . . . . . .10-27

TECHNICAL SPECIFICATIONS – CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-29

TECHNICAL SPECIFICATIONS – ENGINE 640 ADVENTURE-R . . . . . . . . .10-30

TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE-R . . . . . . . .10-32

TECHNICAL SPECIFICATIONS – ENGINE 640 DUKE . . . . . . . . . . . . . . . .10-33

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-35

 

MODEL 2000

TECHNICAL SPECIFICATIONS – ENGINE SC, SUPERMOTO . . . . . . . . . . 10-36

TECHNICAL SPECIFICATIONS – CHASSIS SC, SUPERMOTO . . . . . . . . . 10-38

TECHNICAL SPECIFICATIONS – ENGINE LC4-E, ADVENTURE, DUKE . . .10-39

TECHNICAL SPECIFICATIONS – CHASSIS LC4-E SUPERMOTO . . . . . . . .10-41

TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE-R . . . . . . . .10-42

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-43

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE AUS . . . . . . . . . . .10-44

TECHNICAL SPECIFICATIONS – ENGINE 400 SXC . . . . . . . . . . . . . . . . . 10-45

TECHNICAL SPECIFICATIONS – CHASSIS 400/540 SXC . . . . . . . . . . . . .10-46

MODEL 2001

TECHNICAL SPECIFICATIONS – ENGINE 620 SC, SUPERMOTO . . . . . . 10-47

TECHNICAL SPECIFICATIONS – CHASSIS 620 SC, SUPERMOTO . . . . . . 10-49

TECHNICAL SPECIFICATIONS – ENGINE LC4-E, ADVENTURE, DUKE . . .10-50

TECHNICAL SPECIFICATIONS – CHASSIS LC4-E, SUPERMOTO . . . . . . .10-52

TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 ADVENTURE . . . . . .10-53

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-54

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE USA, AUS . . . . . . .10-55

 

MODELL 2002

TECHNICAL SPECIFICATIONS – ENGINE 625 SC, SUPERMOTO . . . . . . 10-56

TECHNICAL SPECIFICATIONS – CHASSIS 625 SC, SUPERMOTO . . . . . . 10-57

TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE . . . 10-58

TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . . . . . 10-59

TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE . . . . . . . . . 10-60

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . . 10-61

 

MODELL 2003

TECHNICAL SPECIFICATIONS – ENGINE 625 SXC . . . . . . . . . . . . . . . . . 10-62

TECHNICAL SPECIFICATIONS – CHASSIS 625 SXC . . . . . . . . . . . . . . . . 10-63

TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE . . . 10-64

TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . . . . . 10-65

TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 ADVENTURE . . . . . . 10-66

TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . . 10-67

TECHNICAL SPECIFICATIONS – ENGINE 660 SMC . . . . . . . . . . . . . . . . 10-68

TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC . . . . . . . . . . . . . . . 10-69

TIGHTENING TORQUES

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-71

ASSEMBLY CLEARANCE, WEAR LIMIT . . . . . . . . . . . . . . . . . . . . . . . . .10-72

 

PERIODIC MAINTENANCE SCHEDULE:

MODEL 1998

PERIODIC MAINTENANCE SCHEDULE SX, SXC, SC . . . . . . . . . . . . . . .11-2

PERIODIC MAINTENANCE SCHEDULE LC4 COMPETITION, LC4 . . . . .11-3

PERIODIC MAINTENANCE SCHEDULE ADVENTURE-R . . . . . . . . . . . .11-4

PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . . .11-5

 

MODEL1999

PERIODIC MAINTENANCE SCHEDULE SX, SXC, SC . . . . . . . . . . . . . . .11-6

PERIODIC MAINTENANCE SCHEDULE LC4 COMPETITION, LC4 . . . . .11-7

PERIODIC MAINTENANCE SCHEDULE ADVENTURE-R . . . . . . . . . . . .11-8

PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . . .11-9

 

MODEL 2001

PERIODIC MAINTENANCE SCHEDULE 620 SC . . . . . . . . . . . . . . . . . .11-10

PERIODIC MAINTENANCE SCHEDULE LC4-E, ADVENTURE . . . . . . . .11-12

PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-14

 

MODEL 2002

PERIODIC MAINTENANCE SCHEDULE 625 SC . . . . . . . . . . . . . . . . . .11-16

PERIODIC MAINTENANCE SCHEDULE LC4, ADVENTURE . . . . . . . . . .11-18

PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-20

 

MODEL 2003

PERIODIC MAINTENANCE SCHEDULE 625 SXC, 660 SMC . . . . . . . . .11-22

PERIODIC MAINTENANCE SCHEDULE 640 LC4, 640 LC4 ADVENTURE . . .11-24

PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-26

 

WIRING DIAGRAMS:

MODEL1998

WIRING DIAGRAM 400 / 540 SXC . . . . . . . . . . . . . . . . . . . . . .12-3

WIRING DIAGRAM 400 / 620 SC (For Competition) . . . . . . . . .12-5

WIRING DIAGRAM 400 / 620 SC (For Australia) . . . . . . . . . . . .12-7

WIRING DIAGRAM 400 / 620 SC (For Germany) . . . . . . . . . . . .12-9

WIRING DIAGRAM 640 LC4 (For USA) . . . . . . . . . . . . . . . . . . .1211

WIRING DIAGRAM 640 ADVENTURE-R (Dell Orto) . . . . . . . . .12-13

WIRING DIAGRAM 640 DUKE-E . . . . . . . . . . . . . . . . . . . . . . .12-15

WIRING DIAGRAM 620 LC4 COMPETITION . . . . . . . . . . . . . .12-17

WIRING DIAGRAM 400 LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM 640 LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-21

 

MODEL 1999

WIRING DIAGRAM 400 / 540 SXC . . . . . . . . . . . . . . . . . . . . .12-23

WIRING DIAGRAM 400 / 540 SXC (Australia) . . . . . . . . . . . . .12-25

WIRING DIAGRAM 400 / 620 SC . . . . . . . . . . . . . . . . . . . . .12-27

WIRING DIAGRAM 400 / 620 SC (Australia) . . . . . . . . . . . . . .12-29

WIRING DIAGRAM 640 ADVENTURE-R (Dell Orto) . . . . . . . . .12-13

WIRING DIAGRAM 640 ADVENTURE-R (Mikuni) . . . . . . . . . . .12-31

WIRING DIAGRAM 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . .12-33

WIRING DIAGRAM 620 LC4 COMPETITION . . . . . . . . . . . . . .12-17

WIRING DIAGRAM 400 LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM 640 LC4, SUPERMOTO . . . . . . . . . . . . . . .12-21

WIRING DIAGRAM 640 LC4 (USA) . . . . . . . . . . . . . . . . . . . . .12-11

 

MODEL 2000

WIRING DIAGRAM 400 / 620 SC / 620 SC SUPERMOTO . . . . .12-27

WIRING DIAGRAM 640 ADVENTURE-R . . . . . . . . . . . . . . . . .12-31

WIRING DIAGRAM 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . .12-33

WIRING DIAGRAM 400 LC4-E . . . . . . . . . . . . . . . . . . . . . . . .12-19

WIRING DIAGRAM 640 LC4-E, SUPERMOTO . . . . . . . . . . . . .12-21

WIRING DIAGRAM 400 / 640 LC4-E (USA) . . . . . . . . . . . . . . .12-35

MODEL 2001

WIRING DIAGRAM 620 SC / 620 SC SUPERMOTO . . . . . . . . .12-37

WIRING DIAGRAM 640 LC4 ADVENTURE . . . . . . . . . . . . . . .12-39

WIRING DIAGRAM 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . .12-41

WIRING DIAGRAM 400 LC4-E, 400 / 640 LC4-E USA . . . . . . .12-43

WIRING DIAGRAM 640 LC4-E, SUPERMOTO . . . . . . . . . . . . .12-45

 

MODEL 2002

WIRING DIAGRAM 625 SC / 625 SC SUPERMOTO . . . . . . . . .12-47

WIRING DIAGRAM 640 LC4 ADVENTURE . . . . . . . . . . . . . . .12-49

WIRING DIAGRAM 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . .12-51

WIRING DIAGRAM 640 LC4, 640 LC4 SUPERMOTO . . . . . . . .12-53

WIRING DIAGRAM 640 LC4, 640 LC4 SUPERMOTO USA . . . .12-55

 

MODEL 2003

WIRING DIAGRAM 625 SXC . . . . . . . . . . . . . . . . . . . . . . . . .12-57

WIRING DIAGRAM 640 LC4, 640 LC4 SUPERMOTO . . . . . . . .12-59

WIRING DIAGRAM 640 LC4 ADVENTURE . . . . . . . . . . . . . . .12-61

WIRING DIAGRAM 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . .12-63

WIRING DIAGRAM 660 SMC . . . . . . . . . . . . . . . . . . . . . . . . .12-64

Owner’s Manuals

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly