KTM 400-660 LC4 1998-2005 User Manual

8-36E
Checking the throttle valve sensor
NOTE: The following measurement must be taken at a component
temperature of approx. 20°C.
– Open the plug-and-socket connection of the throttle valve sensor.
– Connect a multimeter (measuring range Ω x 1k) to the blue (+) and
the black (-) cable of the throttle valve sensor.
throttle valve sensor resistance: 4 - 6 kΩ
–Now, connect the multimeter to the yellow (+) and the black (-)
cable of the throttle valve sensor.
– As you open the throttle grip slowly, the resistance must change
evenly.
throttle valve sensor resistance: 0-5 kΩ ±1 kΩ
(while opening the throttle grip)
Dismounting and installing the throttle valve sensor
– Disconnect the plug-and-socket connection of the throttle valve
sensor and remove the bolt
1.
–Take the throttle valve sensor off the carburetor.
– When mounting the throttle valve sensor, make sure that the flat
spot at the throttle valve pin
2 engages the groove on the throttle
valve sensor.
– Mount the bolt, however, do not yet tighten fully and adjust the
position of the throttle valve sensor. Secure the bolt with
Loctite 243.
bl
bl
ge
ge
s
s
bl = blue
ge = yellow
s = black
1
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