Description
This 1995 KTM 400 620 EGS EXC SC SX LC4 Duke Factory Engine Service Manual is an authorized reproduction of the original factory service manual. It covers ONLY the engine. If you require information about the chassis consider also getting an owners manual which covers the chassis in more detail.
This cover may vary, it may be black and white based on the printing.
1995 KTM 400 620 LC4 Duke Engine Service Manual Models Coverage
1995 KTM 400 EGS
1995 KTM 400 EXC
1995 KTM 400 Duke
1995 KTM 620 EXC
1995 KTM 620 EGS
1995 KTM 620 Duke
1995 KTM 400 620 EGS EXC SC SX LC4 Duke Engine Service Manual Table of Contents
GENERAL INFORMATIONS
Oil circuit – SX, Super Competition
Changing the engine oil SX, Super Competition
Replacing the microfilter – SX, Super Competition
Oil circuit – EXC, EGS, Duke
Changing the engine oil EXC, EGS, Duke
Changing the fine sreen filter – EXC, EGS, Duke
Changing oil filter
Special roots
REMOVING ENGINE
DISMANTLING THE ENGINE
Drain engine oil
Fitting crankshaft locking bolt
Timing train, Cylinder head
Cylinder
Piston
Chain sprocket
Oil line
Clutch, Primary Gear
Oil pump
Clutch release shaft
Flywheel
Parting of engine housing halves
Shifting mechanism
Transmission
Kickstarter
SERVICING ON INDIVIDUAL COMPONENTS
Left housing half
Right housing half
Crankshaft
Measurement/equalisation 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
Automatic tensioner
Preassembly of automatic tensioner
Oil pump
Oil lines
Microfilter
Kickstarter
Preassembly of kickstarter shaft
Clutch EXC, EGS, Duke
Clutch SX, Super Comp.
Shifting mechanism
Preassembly of gear-change shaft
Shifting mechanism support
Gearbox
Assembly of main shaft
Assembly of take off shaft
Waterpump
Checking the counter balancer shaft
Ignition
ENGINE ASSSEMBLY
Transmission, Shifting mechanism
Alignment of return spring
Pretensioning of the starter spring
Mounting crankshaft
Assembly of engine case
Mounting oil filter
Chain sprocket
Mounting flyv/heel
Oil pump
Timing
Oil Pump Gear Wheel
Clutch
Counter balancer shaft primary pinion
Fitting clutch discs (EXC, ECS, Duke}
Fitting clutch discs (SX, Super Comp.)
Mounting release shaft
Adjustment of clutch disengagement
Piston and Cylinder
Microfilter (SX, Super Competition}
Cylinder head
Timing
Water pump
Cylinder head top section
Automatic tensioner
Adjustment of valve play
Function test auto decompression
Clutch cover
Ignition system
Adjustment of ignition point
Ignition Markings
Marking the counterbalance shaft
Oil lines (SX, Super Competition)
Oil lines (EGS/Duke)
REFITTING THE ENGINE
Installing the engine (SX, Super Comp.)
Installing the engine (EXC, EGS, Duke)
Engine oil
Replacing the microfilter (SX, Super Comp)
ELECTRICAL EQUIPMENT
Checking voltage regulator – rectifier (Shindengen)
Checking voltage regulator – rectifier (ULO)
Checking the capacitor
Check voltage regulator
TROUBLE SHOOTING
TECHNICAL DATA – ENGINE
Technical data engine
Tolerance, assembly clearance
Tightening Torques
LUBE- AND MAINTENANCE-SCHEDULE
WIRING DIAGRAM
Includes wiring diagram for 1995 KTM 350 LC4 as well.
