Page Checking the suction pump for wear — Insert both suction pump rotors in the housing. Page Disassembling the cylinder head and checking parts for wear NOTE: the illustration shows the font cylinder. The procedure for the rear cylinder is identical. NOTE: — Note down the mounting position to ensure that the same bucket tappet is inserted in the same bore during installation.
Page Checking the pistons — Mark the position of the piston arrow in the cylinder to facilitate reassembly and to ensure that the same piston is mounted in the same cylinder again. Page Piston and cylinder identification The cylinder size is impressed in the bottom of the cylinder near the chain tunnel; 1 is size I, 2 is size II.
The piston size is impressed in the top of the piston; 1 is size I, 2 is size II. Page — Place the lubricated piston on the cylinder and clamp the piston rings together with the piston ring clamping band Page Generator cover — Loosen the three bolts on the stator. Take the cable duct out of the generator cover and remove the stator. Page Clutch — checking parts for wear Check the thrust bearing for wear.
Check the front end of the pushrod for wear and blow compressed air through the holes. NOTE: the pushrod is made of nitride steel from the model.
If you are repairing an engine older than the model, replace the old pushrod with the newer version. Page Shift mechanism — checking parts for wear Shift forks Check the leaf for wear. Check the driving bolt for the shift drum for wear. Shift rolls Check the shift rolls for hair cracks and pressure marks. It should be easy to turn the shift rolls on the driving bolts of the shift forks. Page General information on servicing the transmission — Clamp the main shaft in the vise use protective jaws and remove the gears.
Use new lock rings whenever you repair the transmission. Check the tooth profile on the transmission shafts and sliding gears for wear. Page General information on servicing the transmission — Clamp the main shaft or countershaft in the vise use protective jaws and remove the gears. Pull off the bearing ring. Page Checking the freewheel — Insert the freewheel gear in the freewheel.
Page Clean all parts thoroughly before reassembling. Oil pumps NOTE: lubricate the oil pump rotors and the oil pump shaft prior to installation. Page — Apply Loctite to the three remaining oil pump bolts M6x40 and screw in.
Tighten bolts to 10 Nm. Page Transmission — Simultaneously push both transmission shafts into the bearing seats. NOTE: pay attention to the spacing washer on the countershaft.
Page — Insert the crankshaft in the friction bearing. NOTE: — The crankshaft end with the thread for the primary pinion bolt connection must point down. Both conrods should be in the position shown in the illustration. Page Shift mechanism — Mount the locking lever with the spring. Apply Loctite to the M5x20 bolt and tighten to 6 Nm. Page — Screw on the generator-end timing chain tensioning rail.
Apply Loctite to the bolt and tighten to 20 Nm. Page Generator cover — Mount dowel pins on the engine case and put a new gasket in place. M6x30 Position the generator cover and tighten the generator cover bolts to M6x30 A 10 Nm see illustration for bolt lengths.
Page Primary pinion — Mount the woodruff key for the primary pinion in the shaft groove if dismounted. The bore for the pickup ring must face towards the outside. Page — Slide the 25 x 48 x 6. NOTE: the two clutch pressure booster parts are marked with coinciding circles. Page Clutch Cover Clutch cover — A vibration damper is mounted in the outer clutch cover from the model, screw may not be loosened.
Page Oil screen — Insert the oil screen in the opening in the case. Water pump — Page Cylinder head rear with timing chain — Remove the M10x stud bolts, strength class NOTE: you can tell the two strength classes apart by their thread length. Stud bolts in class Page — Push the double timing gear down into the chain tunnel draw the timing chain along the side on the inside.
Page Chain tensioner cylinder rear — Insert the chain tensioner element in the cylinder head bore. NOTE: the housing and tensioning piston of the chain tensioner are compression molded. If the two parts cannot be separated, the chain tensioner must be replaced. Page Camshafts cylinder rear — Insert the two camshafts marked "in re" rear intake camshaft and "ex re" rear exhaust camshaft into the bearings without tilting.
The marks on the camshaft gears must coincide with the flat outer surface of the cylinder head see illustrations. NOTE: — Page — Push the cylinder head and cylinder down. Oil the cylinder head nuts and mount with the washer - see Technical Information. The cylinder head nuts are tightened in 2 stages. Use the special nut Page Chain tensioner cylinder front — Insert the chain tensioning element in the cylinder head bore. Page Camshafts cylinder front — Insert the two camshafts marked "in fr" front intake camshaft and "ex fr" front exhaust camshaft into the bearings without tilting.
The marks on the camshaft gears must coincide with the cylinder head surface see illustrations. The cams on the exhaust camshaft point towards the inside and push open the exhaust valves, the cams on the intake camshaft also point towards the inside, the bucket tappets are not actuated. Page Spark plug shaft inserts — Mount new O-rings on the spark plug shafts and grease.
Push the spark plug shaft inserts all the way in. Insert bolts with the sealing washers and tighten to 10 Nm. Page Checking for loss of current Check for loss of current before you check the rectifier regulator.
The motorcycle can only be started under the following conditions: — You will only be able to start under the following conditions: — If the ignition switch is in the ON position — The motorcycle can only be started under the following conditions: — Ignition lock in the ON position — Emergency-off switch in the ON position — E5 lig-X The auxiliary start relay Page — the diode has no continuity.
Various malfunctions can occur, depending on the type of defect. Page nonrecurring "click". Page — Disconnect the clutch switch connector from the cable tree. A functional check of the ECU can only be performed on an ignition test stand. Since the fuel pressure regulator keeps the fuel pressure constant, the quantity of fuel injected is controlled by the time the injection valve is open. The registered error codes can be read out through the diagnostics connector using the KTM diagnostics tool and deleted after the error has been eliminated.
The ground for the relay coil is switched for several seconds by the control unit with the ignition on during the starting process. A back-pressure valve is installed in the outlet opening which closes when the ignition is switched off, stopping the pump in order to maintain the residual fuel pressure; Page Reducing jets with a 1 mm air hole are connected to the intake port.
Page Pulse generator crankshaft The pulse generator is located under the clutch cover on the right side of the engine. It is an inductive sensor, i.
Page Catalytic converter The catalytic converter is installed in the main silencer and transforms most of the main toxic constituents into non-toxic compounds. It is designed as a three-way catalytic converter and consists of a coiled metal support whose surface is coated with precious metals such as platinum and rhodium; Page Fresh air is drawn into the exhaust resulting in afterburning.
Octane selector connections Adventure only If fuel having at least 95 octane ROZ is not available, you can easily activate the corresponding ignition curve by reducing the ignition timing. Page Installation: behind the headlight mask. Diagnostics connector The diagnostics connector is located under the seat. The diagnostics connector connects the KTM diagnostics tool and the control unit to read error codes or perform function tests.
Side stand switch The side stand switch Fuel pump Total failure: will not start Lack of pressure: power loss limited Pressure regulator same as fuel pump see above see above Injection valve Electric error Page Checking the fuel presure Switch on the ignition, the pump will run for 2 seconds or switch on the pump with the KTM diagnostics tool.
If not, perform the following tests: — Scan the fault memory with the KTM diagnostics tool. Page The signal from the coolant temperature sensor can be scanned with the KTM diagnostics tool see table for voltage figures.
If the displayed value does not correspond to the actual temperature or if an error code is displayed, perform the following tests: — Page If an intake pressure sensor breaks down, exchange the two and scan the values again with the KTM diagnostics tool - if the error is in the other position, replace the affected intake pressure sensor. If the Oil pumps NOTE: lubricate the oil pump rotors and the oil pump shaft prior to installation.
Page 92 — Apply Loctite to the three remaining oil pump bolts M6x40 and screw in. Tighten bolts to 10 Nm. Page 93 Transmission — Simultaneously push both transmission shafts into the bearing seats. NOTE: pay attention to the spacing washer on the countershaft.
Page 94 — Insert the crankshaft in the friction bearing. NOTE: — The crankshaft end with the thread for the primary pinion bolt connection must point down. Both conrods should be in the position shown in the illustration. Page 95 Shift mechanism — Mount the locking lever with the spring.
Apply Loctite to the M5x20 bolt and tighten to 6 Nm. Page 96 — Screw on the generator-end timing chain tensioning rail. Apply Loctite to the bolt and tighten to 20 Nm. Page 97 Generator cover — Mount dowel pins on the engine case and put a new gasket in place. M6x30 Position the generator cover and tighten the generator cover bolts to M6x30 A 10 Nm see illustration for bolt lengths. Page 98 Primary pinion — Mount the woodruff key for the primary pinion in the shaft groove if dismounted.
The bore for the pickup ring must face towards the outside. Page 99 — Slide the 25 x 48 x 6. NOTE: the two clutch pressure booster parts are marked with coinciding circles. Page Clutch Cover Clutch cover — A vibration damper is mounted in the outer clutch cover from the model, screw may not be loosened.
Page Oil screen — Insert the oil screen in the opening in the case. Water pump — Page Cylinder head rear with timing chain — Remove the M10x stud bolts, strength class NOTE: you can tell the two strength classes apart by their thread length. Stud bolts in class Page — Push the double timing gear down into the chain tunnel draw the timing chain along the side on the inside.
Page Chain tensioner cylinder rear — Insert the chain tensioner element in the cylinder head bore. NOTE: the housing and tensioning piston of the chain tensioner are compression molded. If the two parts cannot be separated, the chain tensioner must be replaced. Page Camshafts cylinder rear — Insert the two camshafts marked "in re" rear intake camshaft and "ex re" rear exhaust camshaft into the bearings without tilting.
The marks on the camshaft gears must coincide with the flat outer surface of the cylinder head see illustrations. NOTE: — Page — Push the cylinder head and cylinder down. Oil the cylinder head nuts and mount with the washer - see Technical Information.
The cylinder head nuts are tightened in 2 stages. Use the special nut Page Chain tensioner cylinder front — Insert the chain tensioning element in the cylinder head bore. Page Camshafts cylinder front — Insert the two camshafts marked "in fr" front intake camshaft and "ex fr" front exhaust camshaft into the bearings without tilting. The marks on the camshaft gears must coincide with the cylinder head surface see illustrations.
The cams on the exhaust camshaft point towards the inside and push open the exhaust valves, the cams on the intake camshaft also point towards the inside, the bucket tappets are not actuated.
Page Spark plug shaft inserts — Mount new O-rings on the spark plug shafts and grease. Push the spark plug shaft inserts all the way in. Insert bolts with the sealing washers and tighten to 10 Nm. Page Checking for loss of current Check for loss of current before you check the rectifier regulator.
The motorcycle can only be started under the following conditions: — Page Checking the auxiliary starter relay — Dismount the auxiliary starter relay Adventure. Page Functional check of the auxiliary starter relay Adventure — Pull the auxiliary starter relay out of the bracket. The auxiliary starter relay must switch under the following 2 conditions: — They block in the other direction.
Diodes can have 2 defects: — the diode has no continuity. Various malfunctions can occur, depending on the type of defect. Page Checking the starter relay — Disconnect the negative pole from the battery and dismount the start relay. Page Checking the clutch switch — Disconnect the clutch switch connector from the cable tree.
A functional check of the ECU can only be performed on an ignition test stand. Since the fuel pressure regulator keeps the fuel pressure constant, the quantity of fuel injected is controlled by the time the injection valve is open.
The registered error codes can be read out through the diagnostics connector using the KTM diagnostics tool and deleted after the error has been eliminated.
The ground for the relay coil is switched for several seconds by the control unit with the ignition on during the starting process. A back-pressure valve is installed in the outlet opening which closes when the ignition is switched off, stopping the pump in order to maintain the residual fuel pressure; Page Reducing jets with a 1 mm air hole are connected to the intake port. Page Pulse generator crankshaft The pulse generator is located under the clutch cover on the right side of the engine.
It is an inductive sensor, i. Page Catalytic converter The catalytic converter is installed in the main silencer and transforms most of the main toxic constituents into non-toxic compounds. It is designed as a three-way catalytic converter and consists of a coiled metal support whose surface is coated with precious metals such as platinum and rhodium; Page Ignition coils The ignition coils are mounted directly on the spark plugs; the same ignition coils are used for the injection engine as for the carburetor engine.
Fuel pump relay The fuel pump relay is installed under the seat. Each relay has a coil and at least one load contact; Page Installation: behind the headlight mask. Diagnostics connector The diagnostics connector is located under the seat. The diagnostics connector connects the KTM diagnostics tool and the control unit to read error codes or perform function tests. Side stand switch The side stand switch Fuel pump Total failure: will not start Lack of pressure: power loss limited Pressure regulator same as fuel pump see above see above Injection valve Electric error Page Checking the fuel presure Switch on the ignition, the pump will run for 2 seconds or switch on the pump with the KTM diagnostics tool.
If not, perform the following tests: — Scan the fault memory with the KTM diagnostics tool. Page The signal from the coolant temperature sensor can be scanned with the KTM diagnostics tool see table for voltage figures. If the displayed value does not correspond to the actual temperature or if an error code is displayed, perform the following tests: — Page If an intake pressure sensor breaks down, exchange the two and scan the values again with the KTM diagnostics tool - if the error is in the other position, replace the affected intake pressure sensor.
If the Page input The signal from the 2nd throttle valve sensor can be scanned with the KTM diagnostics tool. In case of an error, perform the following tests: — Apply the ground black cable and the 5-volt supply blue cable to the AM connector with the ignition switched on. Page control unit disconnected.
Lambda probe heater output The lambda probe heater can be tested and controlled with the KTM diagnostics tool. In case of an error, perform the following tests: — Check the positive supply with the ignition on, orange cable at sensor connector CA or CA1. Page The effectiveness of the catalytic converter can only be tested with an emissions tester. Before replacing a catalytic converter suspected to be defective, take a test ride and use the KTM diagnostics tool to check the injection system for proper functioning.
Idle speed control motor Page Both ignition coils must be dismounted but stay connected. If an ignition coil breaks down, exchange the two and control again with the KTM diagnostics tool - if the error is in the other position, replace the affected ignition coil.
If not, perform the following tests: — Page Secondary air valve output The secondary air valve can be tested and controlled with the KTM diagnostics tool. If the secondary air valve fails to switch, perform the following tests: — There should be positive voltage at connector CK Pin 2 ignition on, orange cable. Page Roll angle sensor input The signal from the roll angle sensor can be scanned with the KTM diagnostics tool. The company is also developing a two-cylinder V-shaped four-stroke cc LC8 engine.
This power unit is designed for a powerful motorcycle for a rally and for the future road version of Super Duke. The debut of the novelty will take place in the fall of Parade Horse of the company - the famous model Duke II.
This is an urban enduro-style motorcycle with inch alloy wheels. The futuristic half fairing with two headlights located one above the other looks peculiar. The cc engine is equipped with an electric starter. Both cars are equipped with a four-stroke engine with an electric starter, two-seat saddles and steps for the passenger. The cc modification is also available as the urban enduro LC4-E Supermoto. It is made single, the engine is deprived of an electric starter. Tires are distinguished by off-road tread patterns.
Nevertheless, the presence of a complete set of lighting equipment allowed to certify this car for driving on ordinary roads. For serious off-road raids, the LC4 Adventure-R is designed, which is equipped with a cc engine with an electric starter, a Paris-Dakar-style fairing with two headlights, a liter gas tank and a strong rear trunk.
In collaboration with the Italian company Lem, KTM produces a wide range of children's cross-country motorcycles. The 50 Mini Adventure is designed for the youngest athletes, ages 4 to 6 years. It is equipped with a single-cylinder, two-stroke air-cooled engine with automatic centrifugal clutch and without gearbox. Modification 50SX Junior features a forced engine and increased suspension travels.
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