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KTM 400-660 LC4 1998-2005 User Manual

KTM 400-660 LC4 1998-2005
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11-76F
Collar nut front axle M16x1,5, M17 40 Nm
Collar nut / collar screw front axle M24x1,5 40 Nm
Collar screw front axle (Adventure Supermoto) M24x1,5 60 Nm
Collar screw front axle (400 SXC) M10 40 Nm
Collar nut rear axle M20x1,5 80 Nm
Shock absorber top M10 (M10.9) 45 Nm
Shock absorber bottom M10 (M10.9) 45 Nm
Collar bolts brake disk front M6 (M10.9) Loctite 243 + 14 Nm
Collar bolts brake disk front M6 (M10.9) Loctite 243 + 14 Nm
Collar bolts brake disk front M8 Loctite 243 + 14 Nm
Bolts brake caliper front M8 Loctite 243 + 25 Nm
Bolts brake caliper front (LC4 Supermoto) M10 Loctite 243 + 45 Nm
Allen head bolts brake caliper front (DUKE) M10x1,25 Loctite 243 + 45 Nm
Allen head bolt brake caliper support rear (DUKE) M10 40 Nm
Allen head bolts brake caliper front (660 SMC) M10 60 Nm
Bearing bolt linkage arm/frame M12x1.75 60 Nm
Collar nuts rocker arm bolts M14x1,5 100 Nm
Engine mounting bolt M10 45 Nm
Ball joint for push rod M8 Loctite 243 + 25 Nm
Sprocket bolts with nuts M8 Loctite 243 + 35 Nm
Collar nut swingarm bolt M14x1,5 100 Nm
Clamping bolts top triple clamp (USD 43) M8 20 Nm
Clamping bolts top triple clamp (Duke) M8 15 Nm
Clamping bolts top triple clamp (EXTREME) M8 15 Nm
Clamping bolts top triple clamp (USD 48) M8 20 Nm
Clamping bolts bottom triple clamp (USD 43) M8 15 Nm
Clamping bolts bottom triple clamp (EXTREME) M8 20 Nm
Clamping bolts bottom triple clamp (USD 48) M8 15 Nm
Clamp bolts for front wheel axle clamp M8 10 Nm
Collar nut for eccentric chain adjuster (DUKE) M10 40 Nm
Bolts, handlebar clamp M8 Loctite 243 + 20 Nm
Allen head bolts handle bar support, damped M10 Loctite 243 + 20 Nm
(LC4, LC4-SM, SMC, ADVENTURE, DUKE)
Allen head bolts handle bar support, not damped (SC, SC-SM, SXC) M10 Loctite 243 + 40 Nm
Rim lock M8 5 Nm
Clamping of steering stemm M8 20 Nm
Duke steering stem clamping M8 15 Nm
Steering head screw M20x1,5 12 Nm
Plug for frame oil M16,1,5 25 Nm
Hand guard on handlebar end M8 20 Nm
Fuel cocks M6 6 Nm
Fuel level sensor M5 3 Nm
Subframe M8 Loctite 243 + 35 Nm
Spoke nipple M4.5 5 Nm
Blocking bolt of adjusting ring for spring preload M6 8 Nm
Other bolts on chassis M6 10 Nm
M8 25 Nm
M10 45 Nm
Other collar nuts on chassis M6 15 Nm
M8 30 Nm
M10 50 Nm
TIGHTENING TORQUE - CHASSIS

Table of Contents

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KTM 400-660 LC4 1998-2005 Specifications

General IconGeneral
BrandKTM
Model400-660 LC4 1998-2005
CategoryEngine
LanguageEnglish

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

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