KTM 400-660 LC4 1998-2005, Repair Manual

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9-7E
TROUBLE SHOOTING LC4
TROUBLE
Engine doesn’t crank.
The engine doesn't crank.
The neutral indicator
lamp doesn't light up.
The engine cranks only
with pulled clutch lever
Engine cranks with gear
engaged.
Engine cranks but doesn’t
start.
CAUSE
Operating errror
Discharged battery.
Defect ignition lock or emergency
OFF switch
Blown fuse safe-starting system.
Blown main fuse.
Defect safe-starting system.
Defect safe-starting system.
Operating error
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has
accumulated in the float chamber
Fuel supply interrupted
Flooded engine
Sooty or wet spark plug
Electrode gap too large
Spark plug connector or spark plug
faulty
The plug connection of the CDI-
unit, the pulse generator or the
ignition coil has oxydized
Water in carburetor or jets blocked
REMEDY
Turn on the ignition, switch the gear to neutral and switch
the emergency OFF switch on.
Recharge the battery and investigate the causes for
discharging.
Check ignition lock and emergency OFF switch.
Replace fuse (below the headlight mask).
Remove seat and replace the main fuse.
Check the components of the safe-starting system.
Check the components of the safe-starting system.
Open fuel tap, tank fuel, you did not use choke i.e. the
warmstart device. Pay attention to starting off information
(see driving instructions).
The easily inflammable components of the new fuels
evaporate during longer periods of standstill.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old
fuel from the float chamber. The engine will immediately start
off when the float chamber is filled with new fuel.
Loosen fuel hose at carburettor, lead into a basin and open
fuel tap
– if fuel leaks out, the carburetor might need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Fully open the throttle when starting or exchange the spark
plug, respectively
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug electrode gap to 0,7 mm
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate starter, a strong spark
must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn't produce a spark either,
disconnect the spark plug connector from the ignition cable,
hold it a distance of approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Remove the seat, the right side cover and the fuel tank.
Clean the plug connection and treat it with contact spray
Dismount and clean carburetor