KTM 400-660 LC4 1998-2005, Repair Manual

Page: 60 / 501

CHECKING THE CLUTCH COMPONENTS FOR WEAR . . . . . . . . . . . . . . .5-18
CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR . . . . . . .5-19
PREASSEMBLY OF SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
SHIFT MECHANISM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
DISASSEMBLING AND REASSEMBLING THE WATER PUMP . . . . . . . . . . .5-20
IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION . . . . . . . .5-21
ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
ASSEMBLING THE COUNTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
REMOVING THE INTERMEDIATE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
REPLACING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
CHECKING SECONDARY AIR SYSTEM (SLS) . . . . . . . . . . . . . . . . . . . . . .5-24
IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2) . .5-25
REPLACING THE STATOR (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . .5-25
IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
CHECKING THE STATOR (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
REPLACING THE STATOR (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
CHECKING THE STATOR (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . . .5-27
REPLACING THE STATOR (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . .5-27
INDEX
5-2D
IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING
Read through the following section before commencing work. Then determine the assembly sequence so that the
engine housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing
halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without
damaging it. A wooden panel is best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable
mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing
temperature of approx. 150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the
housing must be replaced.