KTM 60 SX 65 SX 125 200 350 390 Duke EXC SX Repair Workshop Manual 1998-2014 PDF - MKTM60390OPES.zip
This complete service and repair manual, featuring full electrical wiring diagrams, covers the 1998-2014 KTM 60, 65, 125, 200, 350, and 390 models. It delivers every technical detail you need to service, troubleshoot, fix, and rebuild your bike just like an experienced professional technician.
Inside the KTM 60/65/125/200/350/390 1998-2014 workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAKE: KTM
MODEL: 60 SX, 65 SX, 125 EGS, 125 EXE, 125 EXC, 125 EXC Six Days, 125 MXC, 125 SX, 125 SXS, 125 Supermoto, 200 EGS, 200 EXC, 200 EXC Six Days, 200 MXC, 200 SX, 200 SXS, 200 XC, 200 XC-W, 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke MAL, 200 Duke 2013 COL, 200 Duke 2014 COL, 350 EXC‑F EU, 350 EXC‑F AUS, 350 EXC‑F SIX DAYS EU, 350 SX-F EU, 350 SX-F USA, 350 XCF‑W USA, 350 EXC‑F USA, 390 Duke EU, 390 Duke AUS, 390 Duke MAL, 390 Duke 2014 COL
YEAR: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014
"'13-'14 125-200 Duke.pdf"
288 pages; Repair Manual 2013-2014 for 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 2014 COL
"'13-'14 390 Duke.pdf"
204 pages; Repair Manual 2013-2014 for 390 Duke EU, 390 Duke AUS, 390 Duke MAL, 390 Duke 2014 COL
"'12-'13 125-200 Duke.pdf"
267 pages; Repair Manual 2012-2013 for 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 2013 COL
"'12 350 EXC-F, XCF-W"
~1,500 pages, 68 pages PDF, EN/DE/ES/FR/IT; REPAIR MANUAL 2012 for 350 EXC‑F EU, 350 EXC‑F AUS, 350 EXC‑F SIX DAYS EU, 350 XCF‑W USA, 350 EXC‑F USA
"'11 125 Duke.pdf"
195 pages; REPAIR MANUAL 2011 for 125 Duke EU, 125 Duke DE
"'11 350 SX-F (EU_USA).pdf"
220 pages; REPAIR MANUAL 2011 for 350 SX-F EU, 350 SX-F USA
"'99-'06 125-200.pdf"
213 pages; Repair Manual 1999-2006 for 125 SX, 125 SXS, 125 Supermoto, 125 MXC, 125 EXE, 125 EXC, 125 EXC Six Days, 125 EGS, 200 SX, 200 SXS, 200 MXC, 200 EXC, 200 EGS, 200 EXC Six Days, 200 XC, 200 XC-W
"'99-'03 125-200.pdf"
158 pages; Repair Manual Engine 1999-2003 for 125 SX, 125 MXC, 125 EXC, 125 EXE, 125 EGS, 125 SUPERMOTO, 200 SX, 200 MXC, 200 EXC, 200 EGS
"'98-'03 60SX, 65SX.pdf"
92 pages; Repair Manual Engine 1998-2003 for 60 SX, 65 SX
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION...7
1.1 Symbols used...7
1.2 Formats used...7
2 SAFETY ADVICE...8
2.1 Repair Manual...8
2.2 Safety advice...8
2.3 Degrees of risk and symbols...8
2.4 Work rules...8
3 IMPORTANT NOTES...9
3.1 Guarantee, warranty...9
3.2 Operating and auxiliary substances...9
3.3 Spare parts, accessories...9
3.4 Figures...9
4 SERIAL NUMBERS...10
4.1 Chassis number/type label...10
4.2 Key number...10
4.3 Engine number...10
5 MOTORCYCLE...11
5.1 Raising the motorcycle with the rear wheel stand...11
5.2 Taking the motorcycle off of the rear wheel stand...11
5.3 Raising the motorcycle with the front wheel stand...11
5.4 Taking the motorcycle off of the front wheel stand...12
5.5 Raising the motorcycle with the work stand...12
5.6 Removing the motorcycle from the work stand...13
5.7 Starting...13
5.8 Starting the motorcycle to make checks...14
6 FORK, TRIPLE CLAMP...15
6.1 Cleaning the dust boots of the fork legs...15
6.2 Removing fork legs...15
6.3 Installing the fork legs...16
6.4 Disassembling the fork legs...17
6.5 Checking the fork legs...19
6.6 Assembling the fork legs...20
6.7 Removing the lower triple clamp...22
6.8 Installing the lower triple clamp...24
6.9 Checking the steering head bearing play...26
6.10 Adjusting the steering head bearing play...27
7 HANDLEBAR, CONTROLS...28
7.1 Checking the play in the throttle cable...28
7.2 Adjusting the play in the throttle cable...28
7.3 Checking the clutch lever play...28
7.4 Adjusting the clutch cable play...29
8 SHOCK ABSORBER, SWINGARM...30
8.1 Adjusting the spring preload of the shock absorber...30
8.2 Removing the shock absorber...30
8.3 Installing the shock absorber...30
8.4 Removing the spring...31
8.5 Installing the spring...31
9 EXHAUST...33
9.1 Removing the exhaust manifold...33
9.2 Installing the exhaust manifold...34
9.3 Removing the main silencer...35
9.4 Installing the main silencer...36
10 AIR FILTER...37
10.1 Removing the air filter...37
10.2 Installing the air filter...37
11 FUEL TANK, SEAT, TRIM...38
11.1 Opening the filler cap...38
11.2 Closing the filler cap...38
11.3 Removing the seat...38
11.4 Mounting the seat...39
11.5 Removing the passenger seat...39
11.6 Mounting the passenger seat...39
11.7 Removing the fuel tank cover...39
11.8 Installing the fuel tank cover...42
11.9 Removing the fuel tank...44
11.10 Installing the fuel tank...46
11.11 Removing the front spoiler...47
11.12 Fitting front spoiler...47
11.13 Dismounting the front fender...48
11.14 Installing the front fender...48
11.15 Checking the fuel pressure...48
11.16 Changing the fuel filter...50
11.17 Replacing the fuel pump...51
12 WHEELS...53
12.1 Checking the tire air pressure...53
12.2 Checking the tire condition...53
12.3 Checking the brake discs...54
12.4 Front wheel...54
12.4.1 Removing the front wheel...54
12.4.2 Installing the front wheel...54
12.4.3 Removing the brake disc of the front brake...55
12.4.4 Installing the brake disc of the front brake...55
12.5 Rear wheel...56
12.5.1 Removing the rear wheel...56
12.5.2 Installing the rear wheel...56
12.5.3 Removing the brake disc of the rear brake...57
12.5.4 Installing the brake disc of the rear brake...57
13 WIRING HARNESS, BATTERY...62
13.1 Removing the battery...62
13.2 Installing the battery...62
13.3 Disconnecting the negative cable of the battery...63
13.4 Reconnecting the negative cable of the battery...63
13.5 Recharging the battery...63
13.6 Checking the charging voltage...64
13.7 Changing the fuses of individual power consumers...65
14 BRAKE SYSTEM...66
14.1 Checking the front brake linings...66
14.2 Changing the front brake linings...66
14.3 Checking the brake fluid level of the front brake...68
14.4 Adding front brake fluid...68
14.5 Changing the front brake fluid...69
14.6 Checking the rear brake linings...70
14.7 Changing the rear brake linings...71
14.8 Checking the free travel of foot brake lever...72
14.9 Adjusting the free travel of the foot brake lever...73
14.10 Checking the rear brake fluid level...73
14.11 Adding rear brake fluid...74
14.12 Changing the rear brake fluid...74
15 LIGHTING SYSTEM, INSTRUMENTS...76
15.1 Setting kilometers or miles...76
15.2 Adjusting the shift speed RPM 1...76
15.3 Adjusting the shift speed RPM 2...76
15.4 Setting the time...77
15.5 Resetting the service interval display...77
15.6 Checking the headlight setting...77
15.7 Adjusting the headlight range...78
15.8 Changing the parking light bulb...79
15.9 Changing the headlight bulb...80
16 ENGINE...82
16.1 Removing the engine...82
16.2 Installing the engine...85
16.3 Disassembling the engine...90
16.3.1 Preparations...90
16.3.2 Draining the engine oil...90
16.3.3 Removing the chain securing guide...91
16.3.4 Removing the valve cover...91
16.3.5 Removing the spark plug...91
16.3.6 Removing the clutch cover...91
16.3.7 Setting the engine to ignition top dead center...92
16.3.8 Removing the starter motor...92
16.3.9 Removing the timing chain tensioner...93
16.3.10 Removing the camshaft...93
16.3.11 Removing the cylinder head...94
16.3.12 Removing the piston...94
16.3.13 Removing the water pump wheel...95
16.3.14 Removing the alternator cover...96
16.3.15 Removing the rotor...96
16.3.16 Removing the starter drive...97
16.3.17 Removing the balancer shaft drive wheel...97
16.3.18 Removing the gear position sensor...98
16.3.19 Removing the spacer...99
16.3.20 Removing the clutch basket...99
16.3.21 Removing the primary gear...100
16.3.22 Removing the oil pump...100
16.3.23 Removing the shift shaft...101
16.3.24 Removing the shift drum locating...101
16.3.25 Removing the locking lever...101
16.3.26 Removing the oil filter...101
16.3.27 Removing the left engine case...102
16.3.28 Removing the shift rails...103
16.3.29 Removing the shift drum...103
16.3.30 Removing the shift forks...103
16.3.31 Removing the transmission shafts...103
16.3.32 Removing the balancer shaft...104
16.3.33 Removing the crankshaft...104
16.4 Work on individual parts...104
16.4.1 Work on the left section of the engine case...104
16.4.2 Work on the right section of the engine case...105
16.4.3 Changing the shaft seal ring of the water pump...105
16.4.4 Removing the main bearing...106
16.4.5 Checking the radial play of the lower conrod bearing...107
16.4.6 Changing the conrod bearing...108
16.4.7 Changing the balancer shaft bearing...109
16.4.8 Changing the camshaft bearing...109
16.4.9 Work on the cylinder head...110
16.4.10 Checking the cylinder head...111
16.4.11 Checking/measuring the cylinder...111
16.4.12 Checking the piston ring...112
16.4.13 Checking/measuring the piston...112
16.4.14 Checking the piston/cylinder mounting clearance...113
16.4.15 Checking the oil pump...113
16.4.16 Checking the oil pressure regulator valve...113
16.4.17 Checking the clutch...114
16.4.18 Preassembling the clutch...115
16.4.19 Checking the shift mechanism...116
16.4.20 Preassembling the shift shaft...117
16.4.21 Disassembling the main shaft...117
16.4.22 Dismantling the countershaft...118
16.4.23 Checking the transmission...118
16.4.24 Assembling the main shaft...120
16.4.25 Assembling the countershaft...120
16.4.26 Checking the timing assembly...122
16.4.27 Changing the stator...122
16.4.28 Checking the electric starter drive...123
16.4.29 Checking the freewheel...124
16.5 Assembling the engine...124
16.5.1 Installing the crankshaft...124
16.5.2 Installing the balancer shaft...124
16.5.3 Installing the transmission shafts...125
16.5.4 Installing the shift forks...125
16.5.5 Installing the shift drum...125
16.5.6 Installing the shift rails...126
16.5.7 Installing the left engine case...126
16.5.8 Installing the oil filter...127
16.5.9 Installing the locking lever...127
16.5.10 Installing the shift drum locating...127
16.5.11 Installing the shift shaft...128
16.5.12 Installing the oil pump...128
16.5.13 Installing the primary gear...129
16.5.14 Installing the clutch basket...129
16.5.15 Installing the spacer...130
16.5.16 Installing the gear position sensor...130
16.5.17 Installing the balancer shaft drive wheel...131
16.5.18 Installing the starter drive...132
16.5.19 Installing the rotor...133
16.5.20 Installing the alternator cover...133
16.5.21 Installing the water pump cover...133
16.5.22 Installing the piston...134
16.5.23 Installing the cylinder head...135
16.5.24 Installing the camshafts...136
16.5.25 Installing the timing chain tensioner...137
16.5.26 Checking the valve clearance...138
16.5.27 Adjusting the valve clearance...138
16.5.28 Installing the starter motor...138
16.5.29 Installing the clutch cover...139
16.5.30 Installing the spark plug...139
16.5.31 Installing the valve cover...140
16.5.32 Installing the chain securing guide...140
16.5.33 Installing the oil screen...140
16.5.34 Removing the engine from the engine assembly stand...141
17 SHIFT MECHANISM...142
17.1 Adjusting the shift lever...142
18 WATER PUMP, COOLING SYSTEM...143
18.1 Draining the coolant...143
18.2 Filling/bleeding the cooling system...143
18.3 Checking the antifreeze and coolant level...144
18.4 Checking the coolant level...145
19 LUBRICATION SYSTEM...147
19.1 Oil circuit...147
19.2 Checking the engine oil level...147
19.3 Checking the engine oil pressure...147
19.4 Changing the engine oil and oil filter, cleaning the oil screen...149
19.5 Adding engine oil...150
20 IGNITION SYSTEM...151
20.1 Alternator - checking the stator winding...151
21 TECHNICAL DATA...152
21.1 Engine...152
21.2 Engine tolerance, wear limits...152
21.3 Engine tightening torques...153
21.4 Capacities...154
21.4.1 Engine oil...154
21.4.2 Coolant...154
21.4.3 Fuel...154
21.5 Chassis...154
21.6 Electrical system...155
21.7 Tires...155
21.8 Fork...155
21.9 Shock absorber...156
21.10 Chassis tightening torques...156
22 CLEANING/PROTECTIVE TREATMENT...158
22.1 Cleaning the motorcycle...158
22.2 Checks and maintenance steps for winter operation...159
23 STORAGE...160
23.1 Storage...160