2003 KTM 400-660LC4 Repair Manual – PDF DOWNLOAD
DESCRIPTION:
2003 KTM 400-660LC4 Repair Manual – PDF DOWNLOAD
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.
TABLE OF CONTENTS:
2003 KTM 400-660LC4 Repair Manual – PDF DOWNLOAD
HOME……………………………………………………………………………. 0
NOTES AND PREFACE…………………………………………………………….. 1
Title page and file spine………………………………………………….. 1
Important information……………………………………………………… 7
Updating instruction………………………………………………………. 7
Explanation update………………………………………………………… 9
Introduction……………………………………………………………… 11
Reply fax for repair manuals……………………………………………….. 13
TABLE OF CONTENTS…………………………………………………………….. 5
SERVICE-INFORMATIONS………………………………………………………. 1
ADVENTURE-DISCOLORING FUEL TANK…………………………………………. 0
660 SMS OUTER CLUTCH HUB……………………………………………….. 0
BALANCER SHAFT………………………………………………………… 0
LOW OCTANE FUEL ADAPTION……………………………………………….. 0
GENERAL INFORMATION……………………………………………………….. 15
MODELS WITHOUT FRAME OIL……………………………………………….. 17
CHANGING THE ENGINE OIL…………………………………………….. 17
CHANGING THE OIL FILTER…………………………………………….. 17
CHANGING THE MICROFILTER……………………………………………. 18
OIL CIRCUIT……………………………………………………….. 19
OIL CIRCUIT 660 SMC………………………………………………… 20
MODELS WITH FRAME OIL………………………………………………….. 21
CHANGING THE ENGINE OIL…………………………………………….. 21
CHANGING THE FINE SCREEN FILTER……………………………………… 21
CHANGING THE OIL FILTER…………………………………………….. 22
OIL CIRCUIT……………………………………………………….. 23
SECONDARY AIR SYSTEM…………………………………………………… 24
EPC-SYSTEM……………………………………………………………. 25
SPECIAL TOOLS…………………………………………………………. 26
BLEEDING OF THE HYDRAULIC CLUTCH………………………………………… 28
REMOVING AND REFITTING ENGINE………………………………………………. 29
REMOVING THE ENGINE……………………………………………………. 31
REFITTING THE ENGINE…………………………………………………… 33
DISASSEMBLING THE ENGINE…………………………………………………… 35
DRAIN ENGINE OIL………………………………………………………. 37
REMOVING THE ELECTRIC STARTER MOTOR……………………………………… 37
REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES……………………….. 38
REMOVING THE OIL FILTER………………………………………………… 38
REMOVING THE EPC WIRING HARNESS…………………………………………. 38
REMOVING THE IGNITION (KOKUSAN 4K-2)…………………………………….. 38
REMOVING THE IGNITION (SEM)…………………………………………….. 40
REMOVING THE IGNITION (KOKUSAN 4K-3)…………………………………….. 40
REMOVING THE ELECTRIC STARTER DRIVE……………………………………… 41
REMOVING THE CYLINDER HEAD TOP SECTION…………………………………… 42
BLOCKING THE CRANKSHAFT………………………………………………… 43
REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER…………………………. 43
REMOVING CYLINDER HEAD…………………………………………………. 45
REMOVING CYLINDER AND PISTON……………………………………………. 45
REMOVING ENGINE SPROCKET……………………………………………….. 46
REMOVING CLUTCH AND PRIMARY DRIVE……………………………………….. 46
REMOVING THE OIL PUMPS…………………………………………………. 48
REMOVING THE TIMING CHAIN AND THE TIMING GEAR…………………………….. 49
REMOVING THE CLUTCH RELEASE SHAFT……………………………………….. 49
PARTING OF ENGINE HOUSING………………………………………………. 50
REMOVING THE SHIFT MECHANISM……………………………………………. 50
REMOVING THE TRANSMISSION SHAFTS………………………………………… 52
REMOVING THE KICKSTARTER SHAFT………………………………………….. 52
SERVICING INDIVIDUAL COMPONENTS…………………………………………….. 53
WORKING ON THE RIGHT HOUSING HALF……………………………………….. 55
WORKING ON THE LEFT HOUSING HALF………………………………………… 57
CRANKSHAFT……………………………………………………………. 58
MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY………………………….. 59
CHECKING THE PISTON……………………………………………………. 59
MOUNTING INSTRUCTIONS FOR PISTON RINGS…………………………………… 60
PISTON RING END GAP……………………………………………………. 60
MEASURING PISTON AND CYLINDER, DETERMINING THE PISTON FITTING CLEARANCE……… 60
CYLINDER – NIKASIL COATING……………………………………………… 61
RECOATED CYLINDER……………………………………………………… 61
DISASSEMBLING THE CYLINDER HEAD AND CHECKING THE COMPONENTS FOR WEAR………… 62
DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND CHECKING COMPONENTS FOR WEAR…. 63
PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION……………………………… 63
CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR…………………… 64
DISASSEMBLING THE CAMSHAFT AND CHECKING THE COMPONENTS FOR WEAR…………….. 64
PRE-ASSEMBLING THE CAMSHAFT…………………………………………….. 64
AUTOMATIC TENSIONER……………………………………………………. 65
PREASSEMBLY OF AUTOMATIC TENSIONER………………………………………. 65
DISASSEMBLING THE OIL PUMPS AND CHECKING THE COMPONENTS FOR WEAR……………. 65
OIL LINES (SX, SXC)……………………………………………………. 66
OIL LINES (SC)………………………………………………………… 66
OIL LINES (660 SMC)……………………………………………………. 67
OIL LINES (MODELS WITH FRAME OIL)……………………………………….. 67
CHECKING THE KICKSTARTER COMPONENTS FOR WEAR……………………………… 68
PREASSEMBLY OF KICKSTARTER SHAFT………………………………………… 68
CLUTCH COVER………………………………………………………….. 68
REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB………………………. 68
CHECKING THE CLUTCH COMPONENTS FOR WEAR………………………………….. 69
CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR………………………….. 70
PREASSEMBLY OF SHIFT SHAFT……………………………………………… 70
SHIFT MECHANISM SUPPORT………………………………………………… 71
BALANCER SHAFT………………………………………………………… 71
DISASSEMBLING AND REASSEMBLING THE WATER PUMP…………………………….. 71
IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION……………………………. 72
ASSEMBLING THE MAIN SHAFT………………………………………………. 72
ASSEMBLING THE COUNTER SHAFT……………………………………………. 73
REMOVING THE INTERMEDIATE GEAR………………………………………….. 74
CHECKING THE FREEWHEEL…………………………………………………. 74
REPLACING THE FREEWHEEL HUB…………………………………………….. 74
ELECTRIC STARTER MOTOR…………………………………………………. 74
IGNITION (KOKUSAN 4K-2)………………………………………………… 75
CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2)…………………. 75
REPLACING THE STATOR (KOKUSAN 4K-2)……………………………………… 75
IGNITION (SEM)………………………………………………………… 76
CHECKING THE STATOR (SEM)………………………………………………. 76
REPLACING THE STATOR (SEM)……………………………………………… 76
CHECKING THE STATOR (KOKUSAN 4K-3)………………………………………. 77
REPLACING THE STATOR (KOKUSAN 4K-3)……………………………………… 77
ASSEMBLING THE ENGINE……………………………………………………… 79
MOUNTING THE KICKSTARTER UNIT…………………………………………… 81
MOUNTING TRANSMISSION AND SHIFT MECHANISM………………………………… 81
ADJUSTMENT OF RETURN SPRING…………………………………………….. 83
PRETENSIONING OF THE STARTER SPRING……………………………………… 83
MOUNTING CRANKSHAFT……………………………………………………. 83
ASSEMBLY OF ENGINE HOUSING……………………………………………… 84
MOUNTING OIL FILTER……………………………………………………. 85
MOUNTING THE ENGINE SPROCKET……………………………………………. 85
MOUNTING THE TIMING GEAR AND THE TIMING CHAIN…………………………….. 86
MOUNTING THE OIL PUMPS…………………………………………………. 86
MOUNTING THE BALANCER SHAFT AND THE PRIMARY PINION………………………… 87
MOUNTING THE CLUTCH……………………………………………………. 87
MOUNTING THE CLUTCH DISCS………………………………………………. 88
INSTALLING THE CLUTCH RELEASE SHAFT……………………………………… 88
ADJUSTING THE CLUTCH RELEASE……………………………………………. 89
MEASURE DIMENSION „Y“………………………………………………….. 89
MOUNTING PISTON AND CYLINDER……………………………………………. 89
MOUNTING THE CYLINDER HEAD……………………………………………… 90
MOUNTING THE CAMSHAFT, TIMING MARKS……………………………………… 91
MOUNTING THE WATER PUMP………………………………………………… 92
MOUNTING THE CYLINDER HEAD TOP SECTION…………………………………… 93
MOUNTING THE AUTOMATIC TENSIONER………………………………………… 93
AUTOMATIC DECOMPRESSION TESTING…………………………………………. 93
ADJUSTMENT OF VALVE CLEARANCE…………………………………………… 94
MOUNTING THE CLUTCH COVER………………………………………………. 94
MOUNTING THE ELECTRIC STARTER DRIVE……………………………………… 95
MOUNTING THE IGNITION (KOKUSAN 4K-2)…………………………………….. 95
ADJUSTING THE PULSE GENERATOR (KOKUSAN 4K-2)……………………………… 96
MOUNTING THE IGNITION (SEM)…………………………………………….. 96
ADJUSTMENT OF IGNITION POINT (SEM)………………………………………. 97
MOUNTING THE EPC WIRING HARNESS…………………………………………. 97
MOUNTING THE IGNITION (KOKUSAN 4K-3)…………………………………….. 98
ADJUSTMENT OF IGNITION POINT (KOKUSAN 4K-3)………………………………. 98
MOUNTING THE OIL HOSES…………………………………………………. 99
MOUNTING THE CLUTCH RELEASE LEVER……………………………………….. 99
MOUNTING THE ELECTRIC STARTER MOTOR……………………………………… 99
MOUNTING THE WATER HOSES……………………………………………….. 99
POURING IN ENGINE OIL…………………………………………………..100
MOUNTING THE KICKSTARTER AND THE SHIFT LEVER………………………………100
ELECTRICAL………………………………………………………………..101
SUPER COMPETITION 1998………………………………………………….107
CHECKING THE VOLTAGE REGULATOR-RECTIFIER………………………………107
CHECKING THE VOLTAGE REGULATOR……………………………………….107
CHECKING THE CAPACITOR………………………………………………107
LC4 COMPETITION 1998……………………………………………………108
CHARGING SYSTEM…………………………………………………….108
LEAKAGE INSPECTION………………………………………………….108
REMOVING THE BATTERY………………………………………………..109
CHARGING THE BATTERY………………………………………………..109
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR………………………109
CHECKING THE CAPACITOR………………………………………………110
CHECKING THE NEUTRAL SWITCH………………………………………….110
LC4 1998………………………………………………………………111
CHARGING SYSTEM…………………………………………………….111
LEAKAGE INSPECTION………………………………………………….111
REMOVING THE BATTERY………………………………………………..112
CHARGING THE BATTERY………………………………………………..112
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR………………………112
CHECKING THE CAPACITOR………………………………………………113
ELECTRIC STARTER SYSTEM……………………………………………..114
CHECKING THE START AUXILIARY RELAY……………………………………115
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION……………115
CHECKING THE DIODE………………………………………………….115
CHECKING THE STARTER RELAY…………………………………………..116
CHECKING THE ELECTRIC STARTER MOTOR…………………………………..116
CHECKING THE CLUTCH SWITCH…………………………………………..117
CHECKING THE EMERGENCY OFF SWITCH…………………………………….117
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM…………………………117
IGNITION SYSTEM…………………………………………………….118
CDI UNIT…………………………………………………………..119
CHECKING THE IGNITION COIL…………………………………………..119
TROUBLE SHOOTING IN THE IGNITION SYSTEM……………………………….119
EPC SYSTEM…………………………………………………………120
DISMOUNT / RENEW SOLENOID VALVE FOR EPC……………………………….121
CHECK OF SOLENOID VALVE FOR EPC………………………………………121
CONTROLLER OF THE EPC SYSTEM…………………………………………121
CHECK OF EPC SYSTEM MICROSWITCH………………………………………122
REPLACING THE EPC SYSTEM MICROSWITCH………………………………….122
CHECK OF IDLE SWITCH / CONTACT SCREWS…………………………………122
DUKE-E 1998……………………………………………………………123
CHARGING SYSTEM…………………………………………………….123
LEAKAGE INSPECTION………………………………………………….123
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR………………………124
REMOVING THE BATTERY………………………………………………..124
CHARGING THE BATTERY………………………………………………..124
CHECKING THE CAPACITOR………………………………………………125
ELECTRIC STARTER SYSTEM……………………………………………..126
CHECKING THE START AUXILIARY RELAY……………………………………127
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION……………127
CHECKING THE DIODES…………………………………………………128
CHECKING THE CLUTCH SWITCH…………………………………………..128
CHECKING THE EMERGENCY OFF SWITCH…………………………………….128
CHECKING THE STARTER RELAY…………………………………………..129
CHECKING THE ELECTRIC STARTER MOTOR…………………………………..129
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM…………………………129
IDLE SWITCH………………………………………………………..129
IGNITION SYSTEM…………………………………………………….130
CDI UNIT…………………………………………………………..131
CHECKING THE IGNITION COIL…………………………………………..131
SPARK PLUG CONNECTOR………………………………………………..131
CHECKING THE SIDE STAND RELAY………………………………………..131
CHECKING THE SIDE STAND SWITCH……………………………………….132
TROUBLE SHOOTING IN THE IGNITION SYSTEM……………………………….132
SXC 1999………………………………………………………………133
CHECKING THE VOLTAGE REGULATOR……………………………………….133
CHECKING THE CAPACITOR………………………………………………133
SC 1999……………………………………………………………….134
CHECKING THE VOLTAGE REGULATOR……………………………………….134
CHECKING THE CAPACITOR………………………………………………134
CHECKING THE IGNITION COIL…………………………………………..134
DUKE 1999……………………………………………………………..135
CHARGING SYSTEM…………………………………………………….135
LEAKAGE INSPECTION………………………………………………….135
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR………………………136
REMOVING THE BATTERY………………………………………………..136
CHARGING THE BATTERY………………………………………………..136
CHECKING THE CAPACITOR………………………………………………137
ELECTRIC STARTER SYSTEM……………………………………………..138
CHECKING THE START AUXILIARY RELAY……………………………………139
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION……………139
CHECKING THE DIODES…………………………………………………140
CHECKING THE CLUTCH SWITCH…………………………………………..140
CHECKING THE EMERGENCY OFF SWITCH…………………………………….140
CHECKING THE STARTER RELAY…………………………………………..141
CHECKING THE ELECTRIC STARTER MOTOR…………………………………..141
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM…………………………141
CHECKING THE IDLE SWITCH…………………………………………….141
IGNITION SYSTEM…………………………………………………….142
CDI UNIT…………………………………………………………..143
CHECKING THE IGNITION COIL…………………………………………..143
SPARK PLUG CONNECTOR………………………………………………..143
CHECKING THE SIDE STAND RELAY………………………………………..143
CHECKING THE SIDE STAND SWITCH……………………………………….144
TROUBLE SHOOTING IN THE IGNITION SYSTEM……………………………….144
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER……………………………………105
DYNAMIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE…………145
STATIC IGNITION VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE…………..146
STATIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE………….148
STATIC IGNITION VALUES 400/620/625 SC, 660 SMC…………………………150
STATIC GENERATOR VALUES 400/620/625 SC, 660 SMC………………………..152
CHECKING SPEEDOMETER AND SPEEDOMETER SENSOR……………………………….154
FUEL SYSTEM……………………………………………………………….155
MIKUNI BST 40………………………………………………………….159
PART-LOAD SYSTEM……………………………………………………160
FULL-LOAD SYSTEM……………………………………………………161
DISASSEMBLING THE CARBURETOR…………………………………………162
ASSEMBLING THE CARBURETOR……………………………………………164
CHECKING/ADJUSTING THE THROTTLE SENSOR………………………………..165
ADJUST IDLING SPEED…………………………………………………166
ADJUSTING THE THROTTLE CABLE…………………………………………166
CHECK FLOAT LEVEL…………………………………………………..166
DELL’ORTO……………………………………………………………..167
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD)……………………..168
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD)………………………..169
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND)……………………..171
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND)………………………..174
DISASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS)…………………….176
ASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS)……………………….178
CHECK FLOAT LEVEL (DELL’ORTO 38 ND / 40 SD)……………………………181
CHECKING AXIAL CLEARANCE OF FLOAT (DELL’ORTO 38 ND / 40 SD)……………..181
ADJUST HOT START DEVICE (DELL’ORTO 40 SD)……………………………..181
ADJUSTING THE THROTTLE CABLE…………………………………………182
ADJUSTING THE CHOKE CABLE……………………………………………182
KEIHIN FCR 41………………………………………………………….183
DISASSEMBLING THE CARBURETOR…………………………………………184
CHECKING THE CHOKE SLIDE…………………………………………….187
CHECKING THE ACCELERATOR PUMP………………………………………..187
CHECKING THE JET NEEDLE……………………………………………..187
CHECKING THE FLOAT NEEDLE VALVE………………………………………187
CHECKING THE THROTTLE VALVE………………………………………….187
ASSEMBLING THE CARBURETOR……………………………………………188
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR…………………….191
CHECKING THE THROTTLE VALVE SENSOR……………………………………192
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR……………………192
ADJUST IDLING SPEED…………………………………………………193
CHECKING/ADJUSTING THE FLOAT HEIGHT…………………………………..194
KEIHIN FCR-MX 41……………………………………………………….195
DISASSEMBLING THE CARBURETOR…………………………………………196
CHECKING THE CHOKE SLIDE…………………………………………….199
CHECKING THE ACCELERATOR PUMP………………………………………..199
CHECKING THE JET NEEDLE……………………………………………..199
CHECKING THE FLOAT NEEDLE VALVE………………………………………199
CHECKING THE THROTTLE VALVE………………………………………….199
ASSEMBLING THE CARBURETOR……………………………………………200
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR…………………….203
CHECKING THE THROTTLE VALVE SENSOR……………………………………204
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR……………………204
ADJUST IDLING SPEED…………………………………………………205
CHECKING/ADJUSTING THE FLOAT HEIGHT…………………………………..205
TROUBLE SHOOTING…………………………………………………………..207
SX, SXC, SC, SMC)………………………………………………………209
LC4 COMPETITION………………………………………………………..211
LC4…………………………………………………………………..214
TECHNICAL SPECIFICATIONS……………………………………………………217
MODEL 1998…………………………………………………………….217
ENGINE 400/540 SXC………………………………………………….221
CHASSIS 400/540 SXC…………………………………………………223
ENGINE 400/620 SX, SC……………………………………………….224
CHASSIS 400/620 SX, SC………………………………………………226
ENGINE 620 LC4 COMPETITION…………………………………………..227
CHASSIS 620 LC4 COMPETITION………………………………………….229
ENGINE 400/540 SXC………………………………………………….230
CHASSIS 400/640 LC4…………………………………………………233
CHASSIS 640 ADVENTURE-R……………………………………………..234
CHASSIS 640 DUKE-E………………………………………………….235
MODEL 1999…………………………………………………………….217
ENGINE 400/540 SXC, 620 SX…………………………………………..236
CHASSIS 400/540 SXC, 620 SX………………………………………….238
ENGINE 400/620 SC…………………………………………………..239
CHASSIS 400/620 SC………………………………………………….241
ENGINE 620 LC4 COMPETITION…………………………………………..242
CHASSIS 620 LC4 COMPETITION………………………………………….244
ENGINE 400/640 LC4………………………………………………….245
CHASSIS 400/640 LC4…………………………………………………247
ENGINE 640 ADVENTURE-R………………………………………………248
CHASSIS 640 ADVENTURE-R……………………………………………..250
ENGINE 640 DUKE…………………………………………………….251
CHASSIS 640 DUKE……………………………………………………253
MODEL 2000…………………………………………………………….217
ENGINE SC, SUPERMOTO………………………………………………..254
CHASSIS SC, SUPERMOTO……………………………………………….256
ENGINE LC4-E, ADVENTURE, DUKE………………………………………..257
CHASSIS LC4-E SUPERMOTO……………………………………………..259
CHASSIS 640 ADVENTURE-R……………………………………………..260
CHASSIS 640 DUKE……………………………………………………261
CHASSIS 640 DUKE AUS………………………………………………..262
ENGINE 400 SXC……………………………………………………..263
CHASSIS 400/540 SXC…………………………………………………264
MODEL 2001…………………………………………………………….219
ENGINE 620 SC, SUPERMOTO…………………………………………….265
CHASSIS 620 SC, SUPERMOTO……………………………………………267
ENGINE LC4-E, ADVENTURE, DUKE………………………………………..268
CHASSIS LC4-E, SUPERMOTO…………………………………………….270
CHASSIS 640 LC4 ADVENTURE……………………………………………271
CHASSIS 640 DUKE……………………………………………………272
CHASSIS 640 DUKE USA, AUS……………………………………………273
MODELL 2002……………………………………………………………219
ENGINE 625 SC, SUPERMOTO…………………………………………….274
CHASSIS 625 SC, SUPERMOTO……………………………………………275
ENGINE 640 LC4, ADVENTURE, DUKE………………………………………276
CHASSIS 640 LC4, SUPERMOTO…………………………………………..277
CHASSIS 640 ADVENTURE……………………………………………….278
CHASSIS 640 DUKE……………………………………………………279
MODELL 2003……………………………………………………………219
ENGINE 625 SXC……………………………………………………..280
CHASSIS 625 SXC…………………………………………………….281
ENGINE 640 LC4, ADVENTURE, DUKE………………………………………282
CHASSIS 640 LC4, SUPERMOTO…………………………………………..283
CHASSIS 640 LC4 ADVENTURE……………………………………………284
CHASSIS 640 DUKE……………………………………………………285
ENGINE 660 SMC……………………………………………………..286
CHASSIS 660 SMC…………………………………………………….287
TIGHTENING TORQUES……………………………………………………..219
ENGINE…………………………………………………………….288
CHASSIS……………………………………………………………289
ASSEMBLY CLEARANCE, WEAR LIMIT…………………………………………..290
PERIODIC MAINTENANCE SCHEDULE……………………………………………….291
MODEL 1998…………………………………………………………….291
SX, SXC, SC………………………………………………………..293
LC4 COMPETITION, LC4………………………………………………..294
ADVENTURE-R………………………………………………………..295
DUKE………………………………………………………………296
MODEL1999……………………………………………………………..291
SX, SXC, SC………………………………………………………..297
LC4 COMPETITION, LC4………………………………………………..298
ADVENTURE-R………………………………………………………..299
DUKE………………………………………………………………301
MODEL 2001…………………………………………………………….291
620 SC…………………………………………………………….302
LC4-E, ADVENTURE……………………………………………………304
DUKE………………………………………………………………306
MODEL 2002…………………………………………………………….291
625 SC…………………………………………………………….308
LC4, ADVENTURE……………………………………………………..310
DUKE………………………………………………………………312
MODEL 2003…………………………………………………………….291
625 SXC, 660 SMC……………………………………………………314
640 LC4, 640 LC4 ADVENTURE…………………………………………..316
DUKE………………………………………………………………318
WIRING DIAGRAMS……………………………………………………………321
MODEL1998……………………………………………………………..321
400 / 540 SXC………………………………………………………324
400 / 620 SC (For Competition)……………………………………….326
400 / 620 SC (For Australia)…………………………………………328
400 / 620 SC (For Germany)…………………………………………..330
640 LC4 (For USA)…………………………………………………..332
640 ADVENTURE-R (Dell Orto)………………………………………….334
640 DUKE-E…………………………………………………………336
620 LC4 COMPETITION…………………………………………………338
400 LC4……………………………………………………………340
640 LC4……………………………………………………………342
MODEL1999……………………………………………………………..321
400 / 540 SXC………………………………………………………344
400 / 540 SXC (Australia)……………………………………………346
400 / 620 SC……………………………………………………….348
400 / 620 SC (Australia)…………………………………………….350
640 ADVENTURE-R (Dell Orto)………………………………………….334
640 ADVENTURE-R (Mikuni)…………………………………………….352
640 DUKE…………………………………………………………..354
620 LC4 COMPETITION…………………………………………………338
400 LC4……………………………………………………………340
640 LC4, SUPERMOTO………………………………………………….342
640 LC4 (USA)………………………………………………………332
MODEL2000……………………………………………………………..321
400 / 620 SC / 620 SC SUPERMOTO………………………………………348
640 ADVENTURE-R…………………………………………………….352
640 DUKE…………………………………………………………..354
400 LC4-E………………………………………………………….340
640 LC4-E, SUPERMOTO………………………………………………..342
400 / 640 LC4-E (USA)……………………………………………….356
MODEL2001……………………………………………………………..323
620 SC / 620 SC SUPERMOTO……………………………………………358
640 LC4 ADVENTURE…………………………………………………..360
640 DUKE…………………………………………………………..362
400 LC4-E, 400 / 640 LC4-E USA……………………………………….364
640 LC4-E, SUPERMOTO………………………………………………..366
MODEL2002……………………………………………………………..323
625 SC / 625 SC SUPERMOTO……………………………………………368
640 LC4 ADVENTURE…………………………………………………..370
640 DUKE…………………………………………………………..372
640 LC4, 640 LC4 SUPERMOTO…………………………………………..374
640 LC4, 640 LC4 SUPERMOTO USA……………………………………….376
MODEL2003……………………………………………………………..323
625 SXC……………………………………………………………378
640 LC4, 640 LC4 SUPERMOTO…………………………………………..380
640 LC4 ADVENTURE…………………………………………………..382
640 DUKE…………………………………………………………..385
660 SMC……………………………………………………………386
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