5-17E
Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
Checking the kickstarter components for wear
Starter gear
1
Check the bearing for clearance (the starter gear must be in permanent
mesh with the outer clutch hub).
Intermediate starter gear
2
Check the bearing for clearance.
Kick starter shaft
3
Check the toothing for signs of wear.
Ratchet gear
4
Check the ascending surface and the toothing for signs of wear.
Stop bolt
5
Check for signs of wear.
Replace the seal ring
6
NOTE: Due to a parts change from 2000 onwards the seal ring is
blue-green and is to be mounted with the seal lip to the outer side.
Preassembly of kickstarter shaft
– Clamp kickstarter shaft with toothed end in vice (use soft jaw-
covers).
– Mount circlip
7
in lower ring groove.
– Fit spring guide
8
with collar facing downwards and circlip
9
with
sharp edge facing upwards.
– Remove kickstarter shaft from vice and fit ratchet gear spring.
– Mount the ratchet gear
4
on the kickstarter shaft in such a way that
the markings
A
and
B
coincide.
Clutch cover
Balancer shaft bearing
bk
Use the bearing extractor tool 151.12.017.000 with insert to remove
the grooved ball bearing from the bearing seat.
Insert the new bearing into the seat and ensure flush fit.
Seal ring
bl
Use a screwdriver to lever the old shaft seal ring out of the clutch cover.
Insert the new shaft seal ring and ensure flush fit.
Replacing absorbing elements of the outer clutch hub
– Drill open the clutch rivets
bm
in area of the retaining bracket
bn
and
take off the parts.
NOTE: When performing repair work always exchange all 8 absorbing
elements.
!
CAUTION
!
T
HE DAMPING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN
bo
. T
O
ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED
DIRECTLY ON THE PRIMARY GEAR CROWN
,
THE PARTS MUST BE HELD IN POSITION
UNDER TENSION WITH THE CLUTCH RIVETTING TOOL
C
BEFORE RIVETTING
.
– Apply the special tool 546.29.027.000 as shown, screw together and
lock the rivets with a pointed mandrel and a round mandrel.
Locking pressure for the pointed mandrel: approx. 4000 kg
Locking pressure for the round mandrel: approx. 5000 kg
2
5
6
1
8
7
3
4
9
A
B
A
B
10
11
12
14
13
C
Summary of Contents for 400-660 LC4 1998-2005
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Page 3: ...REPAIRMANUAL1998 2005 400 660 LC4 KTM Group Partner...
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Page 158: ...1 2 3 4 5 7 47E...
Page 160: ...6 9 10 11 7 49E...
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Page 167: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 3E CARBURETOR MIKUNI BST 40...
Page 175: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 11E CARBURETOR DELL ORTO PHM 40 SD...
Page 179: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 15E CARBURETOR DELL ORTO PHM 38 ND...
Page 184: ...8 20E CARBURETOR DELL ORTO VHSB 38 QS...
Page 191: ...Repair manual KTM LC4 Art Nr 3 206 014 E 8 27E CARBURATOR KEIHIN FCR 41...
Page 203: ...8 39E Repair manual KTM LC4 Art Nr 3 206 014 E CARBURETOR KEIHIN FCR MX 41...
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Page 370: ...13 3E...
Page 371: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 4E...
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Page 377: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 10E KTM 400 640 SC 1998...
Page 378: ...13 11E...
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Page 401: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 34E...
Page 402: ...13 35E 400 640 LC4 USA...
Page 403: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 36E 400 640 LC4 USA 2000...
Page 404: ...13 37E...
Page 405: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 38E KTM 620 SC 2001...
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Page 407: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 40E...
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Page 411: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 44E...
Page 412: ...13 45E...
Page 413: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 46E KTM 640 LC4 E 2001...
Page 414: ...13 47E 625 SuperComp 2002 SERVICE...
Page 415: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 48E KTM 625 SUPER COMPETITION 2002...
Page 416: ...13 49E SERVICE 640 LC4 ADVENTURE...
Page 417: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 50E KTM 640 LC4 ADVENTURE 2002...
Page 418: ...13 51E SERVICE DUKE 2002...
Page 419: ...Repair manual KTM LC4 Art Nr 3 206 014 E 13 52E KTM DUKE 2002...
Page 424: ...13 57E 660 SMC 2003...
Page 425: ...13 58E Repair manual KTM LC4 Art Nr 3 206 014 E KTM 660 SMC 2003...
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