KTM 400-660 LC4 1998-2005, Repair Manual

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2-6E
Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
Changing the engine oil (models with frame oil)
NOTE: For improved cooling of the engine oil, the front tube of the
frame was integrated into the oil circuit.Thus, when you change the oil,
you also have to drain the engine oil from the front tube and bleed the
oil system.
If the oil system is not bled at all or bled insufficiently, the bearings of
the engine will not get enough lubrication, which in turn may result in
engine failure.
The engine oil change is to be carried out when the engine is still warm.
WARNING
A
N ENGINE HAVING BEEN RUN WARM
,
AND THE ENGINE OIL IN IT ARE VERY HOT
-
DO NOT BURN YOURSELF
.
– Place the motorcycle on a horizontal surface. When working on a
motorcycle with engine guard, remove the latter before commencing
to change the engine oil.
– Remove the two plugs
1
and
2
, and drain oil into a container.
!
CAUTION
!
P
LUG
A
MUST NOT BE REMOVED
,
THIS IS PART OF THE BY
-
PASS VALVE
.
Changing the fine screen filter
Replace the fine screen
3
filter when changing the engine oil.
– Loosen the three bolts and remove the cover.
– Undo the spin-on filter
3
with the corresponding special tool, twist
it off manually and let the engine oil out of the front pipe of the
frame.
– Unscrew plug 4 at the lower end of the front pipe and drain oil ( up
to model 2000 ).
– Clean sealing surfaces on the front pipe
5
, fill new fine screen filter
with engine oil, and oil rubber gasket
6
. Replace fine screen filter
and screw it back in place, your bare hand will do.
!
CAUTION
!
U
SE ONLY ORIGINAL
KTM
FINE SCREEN FILTERS
. U
SING ANOTHER FILTER BRAND CAN
RESULT IN DAMAGE TO THE ENGINE
!
– From model 2001 onwards the drain plug
7
of the frame oil is
located in the oil filter flange, draining is only possible after removing
the oil filter.
– Clean all 3 plugs thoroughly with a fireproof solvent and compressed
air, in order to remove the metal abrasion.
– After all the oil has drained through, clean sealing areas and install
plugs with gaskets. Tighten plug
1
with 30 Nm, plug
2
with 20 Nm
and plug
4
with 10 Nm ( up to model 2000 ). Drain plug of frame oil
( model 2001 onwards ) is to be mounted without a gasket and
tightened to 10 Nm.
1
1
A
A
2
up to Modell 2001 from Modell 2002 on
2
5
3
4
6
7