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. [. . . ] Is the emergency OFF switch in the position ?Is the neutral control lamp on while the ignition is on?Can the engine be started with the clutch pulled?Has the fuse under headlight mask blown? Check the auxiliary starting relay Check the starter relay Check the starter motor 7-39D ge-bl 3 4 r 5 2 0 ra 6 ra s-r ge r-s g w r 8 9 s 1 M G 7 1 2 3 4 5 6 7 8 9 Battery Main fuse Ignition lock Emergency-off switch Auxiliary relay CDI Pulse generator Ignition coil Side stand switch Ignition system From the battery 1 the battery voltage is conducted via the main fuse 2 through the ignition lock 3 and the emergency OFF switch 4, which are both ON, to the side stand relay 5. The side stand relay conducts the battery voltage to the CDI unit 6, if at least one of the following requirements is met : The side stand is up (side stand switch closed). The transmission is switched to neutral (neutral switch closed). The clutch is pulled (clutch switch closed). The pulse generator 7 transmits a signal to the CDI unit 6 upon every rotation of the crankshaft. In the CDI unit, the ignition point is computed from this signal. The ignition pulse is transmitted to the ignition coil 8 (i. e. NOTE: The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery. Therefore, it works only with an intact battery. When the battery is discharged below the threshold level, the voltage can, due to the starting process, drop below the minimum supply voltage required by the ignition. bl . . . blue . brown . yellow . grey . green . orange . red . pink . black . violet . white ! SAFE CAUTION ! AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS. 7-40D CDI unit Check the cables and plug and socket connections of the CDI unit 1. The CDI unit function can only be checked on an ignition test bench. !CAUTION NEVER USE A COMMERCIAL MEASURING DEVICE COMMERCIAL MEASURING DEVICES CAN DESTROY ! TO CHECK THE CDI UNIT. HIGHLY SENSITIVE ELECTRONIC 1 COMPONENTS. Check ignition coil ­ Disconnect all cables and remove the spark plug connector. ­ Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values. MEASUREMENT primary coil secondary coil COLOURS blue/white ­ ground blue/white ­ ignition wire RESISTANCE 0, 425 ­ 0, 575 10, 80 ­ 16, 20 k Spark plug connector Art. -Nr. 3. 206. 006 -E ­ Check the spark plug connector for cracks and fissures. [. . . ] switch 13 ground connection 14 blink signal system 15 horn 16 stoplight switch f. 17 idle switch (N) 18 temperature switch 19 stoplight switch r. 20 spark plug 21 ignition coil 22 generator 23 regulator-rectifier 24 blinker left rear 25 blinker right rear 26 rear-stoplight 27 CDI-unit 28 multip. cont. plug (2) 29 multip. cont. plug (4) 30 multip. cont. plug (6) 31 multip. cont. plug (9) 32 mainfuse 20A 33 run-off/start switch 34 battery 12V 8Ah 36 fan motor 37 starter relay 38 starter engine 39 licence plate lighting 40 clutch switch 41 temperature switch 42 startar auxil. relay Italienisch 1 faro 2 luce di posizione 3 lampegg. [. . . ]