KTM 400-660 LC4 1998-2005 User Manual

4-5E
Removing the ignition (SEM)
– Undo the 4 bolts and remove ignition cover and O-ring.
– Use the crankshaft locking bolt 580.30.080.000 to block the
crankshaft.
– Unscrew collar nut (LH thread) and remove spring disc.
– Fit extractor 580.12.009.000 and pull off flywheel. Use protective
sleeve 510.12.016.000.
– Remove woodruff key from the crankshaft.
–Twist the crankshaft locking bolt out until the crankshaft is no longer
blocked.
!
CAUTION
!
NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID
LOOSENING OF THE MAGNETS
.
Removing the ignition (Kokusan 4K-3)
– Undo the 4 bolts and take off the ignition cover together with the
O-ring.
– Use the crankshaft locking bolt 580.30.080.000 to block the
crankshaft.
– Undo the collar nut (LH thread) and remove the spring washer.
– Mount the extractor 584.29.009.000 and pull off the flywheel.
–Take the woodruff key out of the crankshaft.
–Finally, twist out the crankshaft locking bolt until the crankshaft is no
longer blocked.
! CAUTION !
NEVER USE A HAMMER OR SIMILAR TOOL ON THE FLYWHEEL TO PREVENT
LOOSENING OF THE MAGNETS
.

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