KTM 400-660 LC4 1998-2005, Repair Manual

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5-23F
Repair manual KTM LC4
Art.-Nr
. 3.206.024 -E
Removing the intermediate gear
– Remove the starter cover.
– Pull out the bearing bolt
1
.
– Remove the intermediate gear and the needle bearing.
– Check the parts for signs of wear.
– Insert the intermediate gear with the collar downward into the
housing for preassembly.
– Oil the needle bearing and install it with the bearing bolt.
– Do not yet replace the starter cover.
Checking the freewheel
– Insert the freewheel gear
2
into the freewheel.
– The freewheel gear must turn clockwise.
– The freewheel gear must lock without empty run if turned
anticlockwise.
– Check the reduction gear
3
and the needle bearings for signs of
wear.
– Check the needle bearing of the freewheel gear for signs of wear.
Replacing the freewheel hub
– Squeeze the spreader ring
4
with the circlip pliers and remove it
together with the freewheel.
– Check the freewheel segments for signs of wear.
– Check the freewheel hub sections at the freewheel running surface
for signs of wear.
– Heat the flywheel to a temperature of approx. 80° C (176° F) and
remove the 6 bolts.
! CAUTION !
M
AKE SURE THAT THE FLYWHEEL IS NOT HEATED BEYOND
80° C (176° F)
TO
AVOID LOOSENING OF THE MAGNETS
.
– Carefully tap the side of the freewheel hub with a plastic hammer
and take off the freewheel hub.
– Mount the freewheel hub on the flywheel.
– Clean the thread on the screws and apply Loctite 2701.
– Mount the M6x12.5 screws (2 pieces, strength class 8.8, with dog
point) and tighten to 12 Nm.
– Mount the M6x12 screws (4 pieces, strength class 12.9, without
dog point) and tighten crosswise to 16 Nm.
! CAUTION !
A
LWAYS USE NEW BOLTS
(12.9)
AND APPLY
L
OCTITE
2701
TO THE THREADS
.
– Thoroughly oil the free-wheel and insert it into the freewheel hub.
– Insert the spreader ring into the groove with a pair of circlip pliers
and make sure that it properly rests in the groove.
Electric starter motor
– The starter showed only slight signs of wear after 10.000 starting
processes, and exchanging individual parts must be considered
uneconomical. Therefore, such work is not described in the present
documentation.
– Exchange the O-ring
5
at the starter flange (incl. in the gasket
set).
1
2
3
4
5