KTM 400-660 LC4 1998-2005, Repair Manual

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9-5E
TROUBLE
Engine does not rev high
Engine will not reach full
power
Engine gets to hot,
cooling liquid tmperature
warning lamp lights up
High oil consumption
All lamps that were on
have burned out.
Headlight and parking
light fail.
Flasher lights, brake light,
fan and horn fail.
CAUSE
Carburetor fuel level too high
because
Float needle is dirty or worn out
Float leaks
The cold starting system is
permanently activated due to a
lack of play in the choke cable.
Carburetor jets have loosened.
Defective electronic ignition timing
device.
Fuel supply partically interrupted or
carburetor dirty
Float is not tight
Air filter very dirty
Valve gap to small
Loss of compression because hand
decompressor has no play
Electronical ignition timing faulty
Insufficient cooling liquid
Radiators very dirty
Foam formation in cooling system
Bent cooling hose
Thermostat defective
Buckling gearing ventilation hose
Engine oil level too high
Motor oil too thin (viscosity)
Defective voltage regulator.
Blown fuse.
Blown fuse
REMEDY
Dismount carburetor and check if worn out
Replace float needle
Replace float
Adjust choke cable.
Retighten jets.
Check ignition system
Clean and check fuel system as well as carburetor
Replace the float
Clean or replace air filter
Adjust valve gap
Check setting of the hand decompression cable
Check ignition system
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Clean radiators with water jet
Replace cooling liquid, use anti freeze liquid with brand name
Shorten or replace cooling hose
Dismount and check thermostat (opening temperature 70°C,
158°F) or replace it
Dislocate i.e. replace non-buckling ventilation hose
Check engine oil level when the engine is warm; correct if
necessary
Use thicker engine oil; see chapter „Engine oil“
Remove seat, check connections, Check the voltage
regulator
Replace fuse (below the headlight mask).
Replace fuse (below the headlight mask).