KTM 400-660 LC4 1998-2005 User Manual

LOCTITE 243
LOCTITE 243
LOCTITE 243
LOCTITE 243
Checking the components of the timing mechanism for wear
Timing chain guide 1
Check for signs of wear.
Timing chain tensioner
2
Check for signs of wear.
Timing chain
3
Check rollers for smooth operation and signs of wear.
Timing gear
4
Check teeth for signs of wear.
Camshaft gear
5
Check teeth for signs of wear.
Grooved ball bearing
6
Check clearance.
Safety device
7
Check for signs of wear.
Camshaft
8
Check pivot points and running surfaces for signs of wear.
Disassembling the camshaft and checking the components
for wear
– Remove both the stepped ring bo and the circlip bp. Carefully
remove the decompression cam
bm. Keep a watch on the spring 9.
Supporting pin
bk
Check for signs of wear.
Guide pin
bl
Check for signs of wear.
Decompression cam
bm
Check the contact surfaces towards the supporting pin for signs of
wear.
Spring
9
Check length (minimum length: 7.0 mm/0.275 in).
Camshaft
bn
Check for signs of wear at pivot point A. Minimum diameter of the
pivot point 19.97 mm.
Preassembling the camshaft
– Place spring 9 in the bore, compress and slide decompression cam
bm over it.
– Mount circlip
bp with the sharp side towards the decompression cam.
– Position the open side
B of the circlip between the open spaces of
the decompression cam.
– Slide the step ring
bo with open spaces over the lock washer.
5-12E
8
13
9
12
15
14
6
4
5
2
7
1
3
9
10
11
B
A

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