1996 KTM 620 LC4e Engine Service Manual

Description

This 1996 KTM 620 LC4e Engine Service Manual is an authorized reproduction of the original, out of print manual. It covers engines on 1996 KTM 620 LC4e motorcycles.

The following subjects are covered:

GENERAL INFORMATION – Oil circuit, Changjng the engine oil, Changing the fine screen filter, Changing oil filter, Special toolsREMOVING ENGINEDISMANTLING THE ENGINE – Drain engine oil, Starter, ignition, Double gear; intermediate gear, Timing train, Cylinder head, Cylinder, Piston, Chain sprocket, Clutch, Primary Gear, Oil pumps, Clutch release shaft, Parting of engine housing halves, Shifting mechanism, Transmission, KickstarterSERVICING ON INDIVIDUAL COMPONENTS – Left housing half, Right housing half, Clutch cover, Crankshaft, Measurement/equalization of crankshaft axial play-Piston, Mounting instructions for piston rings, Piston ring end gap, Measuring piston/cylinder, Nikasil coating of cylinder, Recoated Cylinder, Cylinder head, Cylinder head top section, Preassembly of cylinder head top section, Timing, Auto Decompression, Preassembly of auto decompression, Automatic tensioner, Preassembly of automatic tensioner, Oil pumps, Oil lines, Fine filter, Kickstarter, Preassembly of kick starter shaft, Clutch, Replacing damping elements, Water pump, Shifting mechanism, Preassembly of gear- change shaft, Shifting mechanism support,, Checking the counter balancer shaft, Gear-box, Assembly of main shaft,, Assembly of take-off shaft,, Intermediate gear, Check the freewheel, Replace the freewheel hub, Electric starter, Ignition system, Sparkplug, Check stator and pulse generator, Replace the statorENGINE ASSSEMBLY – Kick starter, Transmission, Shifting mechanism, Alignment of return spring, Pretensioning of the starter spring, Mounting crankshaft, Assembly of engine case, Mounting oil filter, Chain-sprocket, Timing, Oil pumps, Counter balancer shaft primary pinion, Clutch, Fitting clutch discs, Mounting release shaft, Adjustment of clutch disengagement, Piston and Cylinder, Cylinder head, Timing, Water pump, Cylinder head top section, Automatic tensioner , Function test auto decompression, Adjustment of valve play, Clutch cover, Freewheel gear; double gear, Flywheel, Starter flange, Adjusting pulse generator, Ignition cover, Starter cover, Oil lines, Electric starter, Engine oilREFITTING THE ENGINEELECTRICAL EQUIPMENT – Charging system, Leakage inspection, Check charging voltage/voltage regulator, Checking the capacitor, Remove battery, Recharging battery, Checking and replacing the diode at the battery, Checking and replacing the clutch diode, Electric starter system, Check auxiliary relay, Check starter relay, Check the electric starter, Ignition system, CDI unit, Check ignition coil, Check spark plug connectorTROUBLE SHOOTING ELECTIICALTROUBLE SHOOTING GENERALTECHNICAL DATA – ENGINE, Technical data – engine, Tolerance, assembly clearance, Tightening TorquesLUBE- AND MAINTENANCE-SCHEDULE

WIRING DIAGRAM