KTM 400-660 LC4 1998-2005, Repair Manual

Page: 69 / 501

Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
Disassembling the cylinder head top section and checking
the components for wear
– Simply pull the rocker arm axles
1
out of the cylinder head top
section. Then take both rocker arms
2
together with thrust washers
3
and
bn
out of the cylinder head top section.
Undo bolt
4
and remove
the following components: Washer
5
Decompression shaft lever
6
Covering disc 7
O-ring 8
Decompression lever spring
9
– Press the decompression shaft
bk
inwards and take it out of the
cylinder head top section together with the washers
bl
.
– Clean all components.
Rocker arm shafts
1
The rocker arm shafts must be free of grooves and should turn easily
within the rocker arms
2 .
Rocker arm rollers
bm
The rocker arm rollers must move smoothly. Rocker arm rollers must be
removed in the case of radial clearance.
Adjusting screws
bo
The contact surfaces of the adjusting screws must be plane.
Decompression shaft bk
Check for smooth operation and clearance in the bearing bore.
Pre-assembling the cylinder head top section
– Insert decompression shaft
bk
with compensation washers
bl
into the
top section.
– Mount the new O-ring
8
, the decompression lever spring
9
and
the cover disc
7
in such a way that the O-ring fits into the recess of
the cover disc.
– Mount the decompression shaft lever
6
.
– Apply Loctite 243 to the thread of bolt 4 and mount the bolt
together with washer 5 .
– Hook the decompression lever spring onto the decompression shaft
lever.
!
CAUTION
!
T
HE DECOMPRESSION SHAFT MUST EXHIBIT NO AXIAL PLAY WHEN THE ALLAN HEAD
BOLT
4
IS TIGHTENED
. T
O ENSURE THAT THE O
-
RING
8
f
ORMS A SEAL
,
IT MUST BE
SLIGHTLY PRESSED AGAINST THE TOP SECTION BY THE COVER DISC
7
. H
OWEVER
,
THE PRESSURE ON THE
O-
RING MUST NOT BE EXCESSIVELY HIGH AS THE
DECOMPRESSION SHAFT WILL BECOME SLUGGISH
. A
DJUST OUT WITH
COMPENSATION WASHERS
bl
IF NECESSARY
.
NOTE: Discs bl are available 0.15 mm, 0.30 mm and 0.50 mm thick.
– Mount new O-rings
bp
on rocker arm shafts
1
.
– Mount rocker arms
2
, thrust washers
3
and rocker arm shafts
1
.
– On the side of the water pump one thrust washer
bn
≠
1.0 mm (0.04
in) must be mounted.
– The axial play on the opposite side is roughly equalized with thrust
washers
3
≠
1.0 (0.04 in) and
≠
0.5 mm (0.02 in).
The axial clearance of the rocker arm axles must be 0.20 - 0.30 mm.
5-11E
13
3
1
1
12
15
15
10
12
14
14
2
13
3
2
6
7
8
9
10
11
4
5
13