KTM 400-660 LC4 1998-2005, Repair Manual

Page: 94 / 501

6-7E
Mount the timing gear and the timing chain
– Insert woodruff key for timing gear into crankshaft and fit timing
gear onto crankshaft with high collar towards housing.
– Fit timing chain onto timing gear and draw up through chain tunnel.
– Insert the timing chain guide
1
, apply Loctite 243 to the Allen head
bolt
2
and mount.
– Apply Loctite 243 to the thread of the flat-head screw
4
.
– Fasten timing chain tensioner 3 with flat head screw.
– Check timing chain tensioner for smooth operation.
– Insert the safety device
5
, apply Loctite 243 to the Allen head bolt
6
and mount.
Mounting the oil pumps
– Clean the sealing surfaces and install the oil pumps in the engine
housing ( A M6x25!)
– Degrease the threads and use Loctite 243 to secure the bolts in their
position.
– Degrease the threads of both bolts
7
, apply Loctite 243 and mount
the retaining bracket
8
.
– Put the stop discs (8.1x15x0.5 mm) onto the oil pump shafts.
– Insert the bearing needles into the oil pump shafts and slide on the
oil pump gears (high collars must face the casing; the small oil pump
gear must face the upper oil pump).
NOTE: From model 2002 onwards both oil pumps are fitted with the
same size of oil pump gear.
– Put on the upper stop discs
9
(8.1x15x0.5 mm) and mount the
locking discs
bk
.
1
2
3
4
5
6
7
8
9
10
A