KTM 400-660 LC4 1998-2005 User Manual

Disassembling the carburetor (Dell’Orto PHM 38 ND)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.
– Remove the two screws and pull the carburetor cover out of the
carburetor together with the throttle slide.
–Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo screw and take the starting piston out of the carburetor.
– Remove the plug
1 together with the seal ring and take off the float
chamber.
– Remove the main jet
2, the main jet holder 3 and the baffle 4.
–Twist out the starting jet
6.
–Twist out the return valve
5.
– Remove the idling jet
8 together with the idle mixture pipe below.
–Twist out the needle jet
7.
– Pull out the pin
9 and remove the float.
– Remove the entire needle valve
bk together with the gasket behind.
8-16E
1
2
3
4
5
6
7
8
9
10

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