KTM 400-660 LC4 1998-2005, Repair Manual

Page: 102 / 501

6-15F
Adjustment of valve clearance
– Adjust piston to ignition top dead center (check marks of flywheel)
and screw crankshaft locking bolt back in.
! CAUTION !
I
F THE PISTON IS NOT IN IGNITION
TDC,
VALVES ARE OPENED AND A CORRECT
ADJUSTMENT IS NOT POSSIBLE
-
IN THAT CASE CRANKSHAFT MUST BE MOVED A
FULL TURN
.
– Valve clearance
A
is measured at cold engine between valve stem
and adjusting screw.
VALVE CLEARANCE 400 : INTAKE 0.20 mm / EXHAUST 0.20 mm
VALVE CLEARANCE 540 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 620 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 625 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 640 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 660 : INTAKE 0.15 mm / EXHAUST 0.15 mm
– Tighten counternuts with 16 Nm.
– Remove the crankshaft locking bolt.
– Mount both valve covers with new gaskets and bolts with copper
seal rings.
– Tighten bolts with 8 Nm.
– Insert and tighten spark plug with 20 Nm.
Mounting the clutch cover
– Pour approx. 30 ml of oil into the crankshaft journal hole.
– Make sure that the two dowels are mounted.
– Fit new gasket and fix with dabs of grease.
– Apply grease to the shaft seal ring in the clutch cover and mount
clutch cover.
– Fit bolts and bump rubber
1
for kickstarter.
NOTE: Bolts
2
must each be provided with a copper seal ring.
– Tighten bolts with 8 Nm.
A
1
2
2