KTM 400 450 520 530 540 620 625 640 660 EXC LC4 SX XC SMC Duke Adventure Supermoto Repair Manual 1998-2009 PDF - MKTM400660OPES.zip
A full factory-level service and repair guide, complete with electrical wiring diagrams, covering the KTM 400, 450, 520, 530, 540, 620, 625, 640, 660 EXC, LC4, SC, SMC, SX, XC, Adventure, Duke and Supermoto models — packed with every technical detail you need to service, troubleshoot, fix, and rebuild your bike just like a trained technician.
Inside the KTM 400, 450, 520, 530, 540, 620, 625, 640, 660 EXC/LC4/SC/SMC/SX/XC/Adventure/Duke/Supermoto 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.
3206054en - KTM 2008 REPAIR MANUAL 450 EXC-R EU, 450 EXC-R AUS_UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS_UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA.pdf
3206064en - KTM 2009 Repair Manual 400 EXC EU, 400 EXC AUS, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC SIX DAYS EU, 450 XC-W USA, 450 XC-W ZA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 450 EXC USA, 530 EXC USA.pdf
KTM 400-520 SX_EXC Racing Service Manual (DE).pdf
KTM 400-660 LC4 Service Manual.pdf
KTM 400-660LC42003 Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,121 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MODEL: KTM
YEAR: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
MODEL: 400 EXC EU, 400 EXC AUS, 400 EXC Racing, 400 EXC Racing USA, 400 LC4, 400 LC4-E, 400 SC, 400 SXC, 400 SX Racing, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC USA, 450 EXC SIX DAYS EU, 450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 450 XC-W USA, 450 XC-W ZA, 520 SX Racing, 520 EXC Racing, 520 EXC Racing USA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 530 EXC USA, 530 EXC-R EU, 530 EXC-R AUS/UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA, 540 SXC, 620 LC4, 620 SC, 620 SC SUPERMOTO, 625 SC, 625 SC SUPERMOTO, 625 SXC, 640 ADVENTURE-R, 640 DUKE, 640 DUKE-E, 640 LC4, 640 LC4 ADVENTURE, 640 LC4-E, 640 SUPERMOTO, 660 RALLY, 660 SMC
--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
"'09 400-450-530.pdf"
248 pages; 2009 REPAIR MANUAL for 400 EXC EU, 400 EXC AUS, 400 XC-W USA, 450 EXC EU, 450 EXC AUS, 450 EXC SIX DAYS EU, 450 XC-W USA, 450 XC-W ZA, 530 EXC EU, 530 EXC AUS, 530 EXC SIX DAYS EU, 530 XC-W USA, 530 XC-W ZA, 450 EXC USA, 530 EXC USA
"'08 450-530 EXC-R_XCR-W.pdf"
191 pages; 2009 REPAIR MANUAL for 450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W USA, 450 XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK, 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W USA, 530 XCR-W ZA
"'98-'05 400-660 LC4"
62.9MB, 1,000+ pages; 400-660LC4 1998-2005 REPAIR MANUAL;
MODEL 1998
400 / 540 SXC
400 / 620 SC (For Competition)
400 / 620 SC (For Australia)
400 / 620 SC (For Germany)
640 LC4 (For USA)
640 ADVENTURE-R (Dell Orto)
640 DUKE-E
620 LC4 COMPETITION
400 LC4
640 LC4
MODEL 1999
400 / 540 SXC
400 / 540 SXC (Australia)
400 / 620 SC
400 / 620 SC (Australia)
640 ADVENTURE-R (Dell Orto)
640 ADVENTURE-R (Mikuni)
640 DUKE
620 LC4 COMPETITION
400 LC4
640 LC4, SUPERMOTO
640 LC4 (USA)
MODEL 2000
400 / 620 SC / 620 SC SUPERMOTO
640 ADVENTURE-R
640 DUKE
400 LC4-E
640 LC4-E, SUPERMOTO
400 / 640 LC4-E (USA)
MODEL 2001
620 SC / 620 SC SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
400 LC4-E, 400 / 640 LC4-E USA
640 LC4-E, 640 LC4-E SUPERMOTO
MODEL 2002
625 SC / 625 SC SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
640 LC4, 640 LC4 SUPERMOTO
640 LC4, 640 LC4 SUPERMOTO USA
MODEL 2003
660 SMC
625 SXC
640 LC4, 640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
MODEL 2004
625 SXC
640 LC4, 640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
660 SMC
MODEL 2005
625 SXC
625 SMC
640 LC4
640 LC4 SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
660 SMC
660 RALLY
"'03 400-660 LC4.pdf"
387 pages; 400-660LC4 1998-2003 REPAIR MANUAL;
400 LC4, 400 LC4-E, 400 SC, 400 SXC, 540 SXC, 620 LC4, 620 SC, 620 SC SUPERMOTO, 625 SC, 625 SC SUPERMOTO, 625 SXC, 640 ADVENTURE-R, 640 DUKE, 640 DUKE-E, 640 LC4, 640 LC4 ADVENTURE, 640 LC4-E, 640 SUPERMOTO, 660 SMC
"'00 400-520 SX_EXC Racing (DE).pdf"
103 pages, German Language; 400-520 SX/EXC Racing Reparaturanleitung
400 SX Racing, 400 EXC Racing, 400 EXC Racing USA, 520 SX Racing, 520 EXC Racing, 520 EXC Racing USA
TABLE OF CONTENTS
HOME...0
MEANS OF REPRESENTATION...8
IMPORTANT NOTES...9
LOCATION OF SERIAL NUMBERS...10
Chassis number...10
Type label...10
Key number (all EXC models)...10
Engine number...11
Fork part number...11
Shock absorber part number...11
MOTORCYCLE...12
Jacking up the motorcycle...12
Removing the motorcycle from the work stand...12
Starting...12
Starting the motorcycle for checking...13
01/FORK, TRIPLE CLAMP...14
Adjusting compression damping of fork...14
Adjusting rebound damping of fork...14
Adjusting spring preload of the fork...14
Bleeding fork legs...15
Cleaning the dust boots of the fork legs...15
Loosening the fork protection...15
Positioning the fork protection...16
Removing the fork legs...16
Installing fork legs...16
Removing the fork protector...17
Installing the fork protector...17
Performing a fork service...18
Disassembling the fork legs...18
cartridge, disassembling...21
Disassembling the compression damping fitting...23
Checking the fork legs...23
Assembling the compression damping fitting...24
Assembling the cartridge...25
Assembling the fork legs...27
Greasing the steering head bearing...31
Removing the lower triple clamp (EXC SIX DAYS, XC‑W USA, EXC USA)...31
Installing the lower triple clamp (EXC SIX DAYS, XC‑W USA, EXC USA)...32
Removing the lower triple clamp (EXC EU, EXC AUS, XC‑W ZA)...32
Installing the lower triple clamp (EXC EU, EXC AUS, XC‑W ZA)...33
Checking the play of the steering head bearing...34
Adjusting play of steering head bearing (EXC SIX DAYS, XC‑W USA, EXC USA)...34
Adjusting play of steering head bearing (EXC EU, EXC AUS, XC‑W ZA)...35
02/HANDLEBAR, INSTRUMENTS...36
Handlebar position...36
Adjusting handlebar position...36
Adjusting basic position of clutch lever...38
Checking the choke cable routing (EXC EU, EXC SIX DAYS)...38
Checking the choke cable play (EXC EU, EXC SIX DAYS)...38
Adjusting the choke cable play (EXC EU, EXC SIX DAYS)...38
Checking of the routing of the throttle cable...39
Checking the play in the throttle cable...39
Adjusting the play in the throttle cable...39
03/FRAME...40
Removing the engine sprocket cover...40
Installing the engine sprocket cover...40
04/SHOCK ABSORBER, SWINGARM...41
Adjusting high-speed compression damping of the shock absorber...41
Adjusting the low-speed compression damping of the shock absorber...41
Adjusting rebound damping of shock absorber...42
Measuring rear wheel sag unloaded...42
Checking static sag of shock absorber...42
Checking riding sag of shock absorber...43
Adjusting spring preload of the shock absorber...43
Adjusting riding sag...44
Removing the shock absorber...44
Installing the shock absorber...44
Performing a shock absorber service...45
Removing the spring...45
Disassembling the shock absorber...46
Disassembling the piston rod...47
Disassembling the seal ring retainer...48
Replacing the pilot bushing...49
Checking the shock absorber...49
Disassembling the rebound adjuster...50
Removing the heim joint...51
Installing the heim joint...51
Assembling the rebound adjuster...52
Assembling the seal ring retainer...53
piston rod, assembling...53
Assembling the damper...55
Bleeding and filling the damper...57
Filling the damper with nitrogen...59
Installing the spring...60
05/EXHAUST...62
Removing main silencer...62
Installing the main silencer...62
Removing the manifold...62
Installing the manifold...62
06/AIR FILTER...63
Dismounting the air filter box lid...63
Installing the air filter box lid...63
Removing the air filter...63
Installing the air filter...63
Cleaning air filter...64
Removing the carburetor connection boot...64
Installing the carburetor connection boot...64
07/FUEL TANK, SEAT, TRIM...65
Opening filler cap...65
Closing filler cap...65
Removing the seat...65
Mounting the seat...65
Dismounting the fuel tank...65
Installing the fuel tank...66
Fuel tap...67
08/MASK, FENDER...68
Removing the front fender...68
Installing the front fender...68
Removing headlight mask with headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...68
Refitting the headlight mask with the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...68
Removing the start number plate (XC‑W USA)...69
Installing the start number plate (XC‑W USA)...69
09/FRONT WHEEL...70
Removing the front wheel...70
Installing the front wheel...70
Checking the brake discs...71
Removing the front brake disc...71
Installing the front brake disc...72
Checking the tire condition...72
Checking tire air pressure...72
Checking spoke tension...73
10/REAR WHEEL...74
Removing the rear wheel...74
Installing the rear wheel...74
Removing the rear brake disc...75
Installing the rear brake disc...75
Checking chain tension when fitting rear wheel...75
Adjusting chain tension - fitting rear wheel...76
Checking the chain tension...76
Adjusting chain tension - after checking...77
Adjusting the chain tension...77
Adjusting chain guide...78
Checking the rear sprocket / engine sprocket for wear...78
Checking chain wear...79
Checking for chain dirt accumulation...79
Cleaning the chain...79
11/WIRING HARNESS, BATTERY...80
Removing a fuse...80
Installing the fuse...80
Removing the battery...80
Installing the battery...81
Recharging the battery...81
Checking the closed current...82
Checking the charging voltage...82
Checking the voltage regulator...83
Checking the charging current...84
Checking the starter relay...84
13/BRAKE SYSTEM...86
Checking the front brake linings...86
Removing front brake linings...86
Mounting front brake linings...86
Changing the front brake linings...87
Checking free travel of hand brake lever...88
Adjusting basic position of handbrake lever (all XC‑W models)...88
Adjusting free travel of handbrake lever (all EXC models)...88
Checking the brake fluid level of the front brake...89
Adding front brake fluid...89
Changing the front brake fluid...90
Checking rear brake linings...91
Removing rear brake linings...91
Mounting rear brake linings...91
Changing the rear brake linings...92
Checking free travel of foot brake lever...93
Adjusting basic position of foot brake lever...93
Checking the brake fluid level of the rear brake...93
Adding rear brake fluid...94
Changing the rear brake fluid...94
14/LIGHTING SYSTEM, INSTRUMENTS...96
Adjusting the speedometer functions...96
kilometers or miles, setting...96
Activating the additional functions...97
Setting the wheel circumference...97
Setting the clock...98
Checking the headlamp setting (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...98
Adjusting the beam width of the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)...98
30/ENGINE...100
Removing the engine...100
Installing the engine...101
30/DISASSEMBLING THE ENGINE...103
Preparations...103
Draining the engine oil...103
Removing the oil filter...103
Draining the gear oil, removing the gear oil screen...103
Removing the starter engine...104
Removing the spark plug...104
Removing the valve cover...104
Removing the shift lever...104
Removing the generator cover...105
Setting the engine to ignition top dead center...105
Removing the timing chain tensioner...106
Removing the camshaft...106
Removing the cylinder head...106
Removing the piston...106
Removing the rotor...107
Removing the balance weight...107
Removing the timing chain guide rail...107
Removing the timing chain tensioning rail...108
Removing the timing chain securing guide...108
Removing the timing chain...108
Removing the ignition pulse generator...108
Removing the suction pump...108