KTM 400-660 LC4 1998-2005 User Manual

6-15F
Adjustment of valve clearance
– Adjust piston to ignition top dead center (check marks of flywheel)
and screw crankshaft locking bolt back in.
! CAUTION !
I
F THE PISTON IS NOT IN IGNITION TDC, VALVES ARE OPENED AND A CORRECT
ADJUSTMENT IS NOT POSSIBLE
- IN THAT CASE CRANKSHAFT MUST BE MOVED A
FULL TURN
.
– Valve clearance
A is measured at cold engine between valve stem
and adjusting screw.
VALVE CLEARANCE 400 : INTAKE 0.20 mm / EXHAUST 0.20 mm
VALVE CLEARANCE 540 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 620 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 625 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 640 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 660 : INTAKE 0.15 mm / EXHAUST 0.15 mm
– Tighten counternuts with 16 Nm.
– Remove the crankshaft locking bolt.
– Mount both valve covers with new gaskets and bolts with copper
seal rings.
– Tighten bolts with 8 Nm.
– Insert and tighten spark plug with 20 Nm.
Mounting the clutch cover
– Pour approx. 30 ml of oil into the crankshaft journal hole.
– Make sure that the two dowels are mounted.
– Fit new gasket and fix with dabs of grease.
– Apply grease to the shaft seal ring in the clutch cover and mount
clutch cover.
– Fit bolts and bump rubber
1 for kickstarter.
NOTE: Bolts
2 must each be provided with a copper seal ring.
– Tighten bolts with 8 Nm.
A
1
2
2

KTM 400-660 LC4 1998-2005 Specifications

General

Brand	KTM
Model	400-660 LC4 1998-2005
Category	Engine
Language	English

Summary

REMOVING AND REFITTING ENGINE

REMOVING THE ENGINE

Detailed steps for safely removing the engine from the motorcycle frame.

REFITTING THE ENGINE

Detailed steps for correctly reinstalling the engine into the motorcycle frame.

DISASSEMBLING THE ENGINE

REMOVING THE CYLINDER HEAD

Steps for removing the cylinder head assembly from the engine.

PARTING OF ENGINE HOUSING

Instructions for separating the engine crankcase halves.

SERVICING ON INDIVIDUAL COMPONENTS

WORKING ON THE RIGHT HOUSING HALF

CRANKSHAFT

Technical specifications and checks for the crankshaft.

CHECKING THE PISTON

DISASSEMBLING THE CAMSHAFT AND CHECKING THE COMPONENTS FOR WEAR

Steps to disassemble the camshaft and inspect its components for wear.

ASSEMBLING THE ENGINE

ASSEMBLY OF ENGINE HOUSING

MOUNTING THE CLUTCH

MOUNTING THE CYLINDER HEAD

ELECTRICAL

ELECTRIC STARTER SYSTEM

IGNITION SYSTEM

FUEL SYSTEM

MIKUNI BST 40

DELL’ORTO

KEIHIN FCR 41

TROUBLE SHOOTING

TROUBLE SHOOTING (SX, SXC, SC, SMC)

Common issues and solutions for SX, SXC, SC, and SMC models.

TROUBLE SHOOTING (LC4 COMPETITION)

Common issues and solutions for LC4 Competition models.

TROUBLE SHOOTING (LC4)

Common issues and solutions for LC4 models.

CHASSIS

DISMOUNTING/MOUNTING THE CHASSIS COMPONENTS

OVERHAULING THE CHASSIS COMPONENTS

REPLACING THE FRONT WHEEL BEARINGS

REPLACING THE REAR WHEEL BEARINGS

TIGHTENING TORQUE

ENGINE

Specific torque values for engine assembly bolts and nuts.

CHASSIS

Specific torque values for chassis assembly bolts and nuts.

PERIODIC MAINTENANCE SCHEDULE

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

Treat electrical contacts and switches with contact spray

WIRING DIAGRAMS

DETAIL WIRING DIAGRAMS

Detailed wiring diagrams for various models and systems.

EXPLANATION OF CONNECTORS, CABLE COLORS