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. [. . . ] CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. AVOID QUICK CHARGING IF POSSIBLE. off load voltage Volt >12. 7 ~12. 5 ~12. 2 ~12. 0 ~11. 8 charging level % 100 75 50 25 0 charging time 0. 8 A ­­ 4h 7h 11 h 14 h charging voltage max. 14. 4 V 7-34D Checking the capacitor ­ Pull main fuse out of the fuse holder. ­ Discharge the capacitor by bridging the two terminals with a screwdriver and remove. ­ Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1. ­ When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. ­ The test lamp must go out after 0, 5-2 seconds (depending on the lamp capacity). ­ If the test lamp does not go out or does not light up at all, the capacitor is faulty. 1 !WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. Repair manual KTM LC4 Art. -Nr. 3. 206. 006 -E 7-35D ge-bl ge-r 5 r s 4 r-w 8 9 g-s ge 1 ge M 7 br G 1 2 3 4 5 6 7 8 9 Battery Ignition lock Emergency off switch Auxiliary relay Tip switch built in emergency off switch Neutral switch Clutch switch Start relay Starter motor Electric starter system The system is equipped with a safety mechanism. Electric starting is only possible when the ignition lock is in the position the emergency OFF switch is in the position the transmission is switched to neutral or the clutch is pulled. Function of the electric starter system: From the battery 1 the battery voltage is transmitted via the ignition lock 2 and the emergency OFF switch 3 to the coil of the auxiliary starting relay 4 and to the tip switch 5. The contact of the auxiliary starting relay prevents starting unless at least one of the following requirements is met : The transmission must be switched to neutral (neutral switch 6 is closed). When the tip switch 5 is operated, the starter motor 9 is switched on via the starter relay 8. bl . . . blue . brown . yellow . grey . green . orange . red . pink . black . violet . white ge-bl 2 3 6 7-36D Check start auxiliary relay ­ Remove headlight mask and remove the start auxiliary relay (cable colours red and red-white). A ­ Connect the start auxiliary relay to a 12 V battery as shown in the illustration. ­ Use an ohmmeter to measure the continuity between the terminals A and B. Reading 0 relay intact Reading relay defect B Checking the auxiliary starting relay for faultless operation Art. -Nr. 3. 206. 006 -E Preparation: ­ Connect an ohmmeter or a continuity tester to the cables of the auxiliary starting relay (colors: red and red/white). The auxiliary starting relay must respond in either of the following two cases: Put in a gear and slowly pull the clutch lever. [. . . ] 26 fanal. post. di freno 27 CDI-seatola 28 connettore a 2 poli 29 connettore a 4 poli 30 connettore a 6 poli 31 connettore a 9 poli 32 fusibile principale 20A 33 disinseritor/partire 34 batteria 12V 8Ah 35 EPC 36 ventilatore 37 rele d'avviamento 38 mot. d'avviamento elettr. ausiliario 43 interrutore carburatore 44 valvola elettromagnetica 45 condensatore 46 trasmettitore d'impulsi 47 connettore a 12 poli 48 diodo 49 3. secondo marcia 50 2. secondo marcia 51 connettore a 3 poli 52 rele del cavalleto later 53 int del cavalleto later Franz sisch 1 phare 2 feu de position 3 clignoteur av. droit 5 temoin de temperature 6 ind. de point mort 7 eclair. comp. vitesse 8 temoin de feu route 9 temoin de clignoteur 10 contact. d'allum. de temperature 19 contact. arr. de stop 20 bougie 21 bobine d'allumage 22 generateur 23 regulat. redresseur 24 clign. arr. gauche 25 clign. arr. droit 26 feu arr. et de stop 27 boitier CDI 28 connect. multiple (2) 29 connect. multiple (4) 30 connect. multiple (6) 31 connect. multiple (9) 32 fusible principal 20A 33 bout. de demar/arr. d'urg 34 batterie 12V 8Ah 35 EPC 36 ventilateur 37 relaise de demarreur 38 demarreur electrique 39 ecl. plaque d. immat. 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