KTM 400-660 LC4 1998-2005, Repair Manual

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Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
6-4E
Adjustment of return spring
– Engage second or third gear.
– Check free travel of slide plate and check shift pin play.
– The free travel of the slide plate is the path this component travels
until the shift roller is moved. The return spring pressure will be felt.
Proceeding from the basic position, this free travel
A
should be
identical for upward and downward movement.
– If necessary, the free travel must be readjusted by adjusting the
return spring.
– For this purpose, remove the shift shaft and bend the return spring
by an appropriate amount at points
B
using a pair of pliers. Refit
shift shaft. After the shifting shaft has been fitted, the return spring
must rest against shift pin
1 and against the centering cup on the
shift mechanism support.
– If necessary, bend the return spring accordingly.
Pretensioning of the starter spring
– Fit kickstarter onto kickstarter shaft, turn one revolution in starting
direction and hold in this position.
– Mount the stop bolt 2 together with a new seal ring and tighten it
manually.
!
CAUTION
!
I
T MUST BE POSSIBLE TO MOUNT THE STOP BOLT WITHOUT APPLYING EXCESSIVE
FORCE
. I
F IT IS NOT POSSIBLE TO MOUNT THE STOP BOLT MANUALLY
,
TURN THE
KICKSTARTER SHAFT FURTHER AGAINST THE FORCE OF THE SPRING UNTIL THE STOP
BOLT CAN BE MOUNTED
.
– Move kickstarter to stop and remove.
– Tighten stop bolt
2
with 50 Nm.
– Place O-ring
3
(22x1 mm) and inner ring
4
of roller bearing on the
counter shaft with the collar facing the gear.
– Mount stop disc
5
(20.2x35x1 mm) onto the main shaft.
Mounting crankshaft
– Grease the shaft seal ring of the crankshaft and thoroughly oil the
roller bearing of the crankshaft.
– Fit mounting sleeve onto crankshaft and place crankshaft into
bearing.
1
B
2
3
4
5