KTM 400-660 LC4 1998-2005 User Manual

3-5E
Mounting the engine
– Lift the engine into the frame and position.
– Mount the screw
1 and the swing arm pivot 2 but do not tighten
yet.
– Mount the engine retaining brackets
3 on the left and right.
–Tighten the swing arm pivot
2 to 100 Nm.
M8 engine fastening bolts: 40 Nm
M10 engine fastening bolts: 70 Nm
–Tighten the jet bolt
4 to 10 Nm.
– Connect all of the electric socket connections to the engine.
–Tighten the banjo bolt
5 to 15 Nm.
Starting with the 2003 model:
–Tighten the 3 crews
6 on the clutch slave cylinder to 10 Nm.
– Mount the chain.
 WARNING 
W
HEN MOUNTING THE CHAIN JOINT MAKE SURE THAT THE CLOSED SIDE OF THE
RETAINER POINTS IN THE RUNNING DIRECTION
.
– Put the chain damping panel 7 and the chainguard 8 in place and
fasten with the two screws
9.
1
2
3
4
5
6
6
9
7
8

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