Segment:
High-performance dual-sport/adventure motorcycle.
Competitors:
BMW GS series (smaller displacement), Honda Transalp, Suzuki DR series, Yamaha XT series during the same era.
Vehicle Focus:
Off-road capability with on-road usability, known for robust single-cylinder engine.
Benefit:
Enables owners and mechanics to perform all necessary maintenance and repairs, maximizing longevity and performance.
Model Years Covered:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Type:
Workshop Service Manual for Repair
Engine And Powertrain:
Full coverage of LC4 engine, including disassembly, assembly, tuning, and troubleshooting.
Chassis And Suspension:
Detailed procedures for front fork, rear shock absorber, swingarm, and frame maintenance/repair.
Brakes:
Comprehensive brake system service, including hydraulic components, pads, and discs.
Electrical System:
Wiring diagrams, troubleshooting for ignition, lighting, and charging systems.
Fuel System:
Carburetor (likely Mikuni), fuel pump, and fuel tank service procedures.
Cooling System:
Radiator, coolant flow, water pump, and associated plumbing.
Exhaust System:
Installation, removal, and inspection of exhaust components.
Wheels And Tires:
Tire changing, wheel bearing service, spoke tensioning (if applicable).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, and general upkeep.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues.
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly.
Adjustments:
Carburetor tuning, clutch adjustment, brake lever adjustment, and suspension setup.
Installation And Removal:
Guidance on removing and installing all major components and sub-assemblies.
Depth:
Comprehensive, covering everything from basic checks to complete engine rebuilds.
Visuals:
Detailed illustrations, exploded diagrams, and photos for clear procedural guidance.
Special Tools:
Identification and usage instructions for specific KTM special service tools.
Specifications:
Precise torque values, wear limits, fluid capacities, and other critical data.
Engine Design:
Single-cylinder, four-stroke, liquid-cooled (LC4)
Displacement:
Approximately 659cc (based on LC4 nomenclature, specific variant may differ slightly).
Bore X Stroke:
Specific values not in product info, but typical for LC4.
Horsepower Range:
Typically 40-50 HP, depending on specific tuning and model variant.
Torque Range:
Strong low-end torque characteristic of LC4 engines.
Fuel Delivery:
Carburetor (likely Mikuni BST series, e.g., BST40 or similar).
Fuel Type:
Unleaded Gasoline
Ignition Type:
Digital CDI
Wheelbase:
Varies by specific model variant, but generally around 1400-1450mm.
Seat Height:
High, typical for dual-sport, often around 900mm+.
Dry Weight:
Varies by model, typically 140-160 kg.
Fuel Capacity:
Typically 11-18 liters depending on the specific fuel tank fitted.
Safety Certification:
European type approval standards (e.g., EU regulations).
Braking System:
Hydraulic disc brakes front and rear.
Suspension Features:
Adjustable front forks (compression, rebound) and rear shock absorber (preload, damping).
Frame Construction:
Chromoly steel trellis frame.
Infotainment System:
Basic analog instrumentation (speedometer, tachometer, odometer, warning lights). No advanced infotainment.
Rider Aids:
No electronic rider aids (e.g., ABS, traction control) typically found on this model.
Connectivity Features:
None.
Oil Change Interval:
Typically 3,000-5,000 km or annually, refer to manual for precise intervals.
Valve Clearance Check:
Usually around 5,000-10,000 km, crucial for LC4 engine health.
Engine Oil Type:
High-quality motorcycle-specific 4-stroke engine oil, e.g., SAE 10W-40 or 15W-50, meeting JASO MA standards.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid.
Fork Oil Type:
Specific suspension fluid (e.g., WP suspension oil or equivalent), viscosity typically around 5W or 10W.
Lc4 Common Points:
Valve clearance drift, potential for kickstarter mechanism wear, carburetor jetting sensitivity, attention to cooling system maintenance.
Preventative Measures:
Regular oil changes with correct oil, diligent valve clearance checks, cleaning air filter, ensuring proper cooling system function.
