KTM 400-660 LC4 1998-2005, Repair Manual

Page: 95 / 501

6-8F
Repair manual KTM LC4
Art.-Nr
. 3.206.024 -E
Mounting the balancer shaft and the primary pinion
– Fit balancer shaft in the bearing.
– Mount woodruff key in crankshaft and place primary pinion on the
crankshaft. When doing so, adjust the teeth of the primary pinion
and the balancer shaft in such a way that the markings
A
and
B
coincide.
– Apply Loctite 243 to the crankshaft thread.
– Mount spring ring and hexagon nut and tighten hexagon nut to 170
Nm.
! CAUTION !
I
F THE BALANCER SHAFT IS NOT INSTALLED ALSO REMOVE BOTH GROOVED BALL
BEARINGS
(
IN THE CLUTCH COVER AND IN THE ENGINE HOUSING
). O
THERWISE THE
GROOVED BALL BEARINGS WOULD DROP OUT OF THE BEARING SEATS AND CAUSE
ENGINE DAMAGE AS SOON AS THE ENGINE HEATS UP
.
Mounting the clutch
– Fit kickstarter intermediate gear
1
onto counter shaft with
clearance space towards housing.
– Slide the inner ring and the needle bearing
2
onto the main shaft.
– Fit outer clutch hub and outer stop disc
3
(22.2x35x3 mm).
– Degrease the thread of the main shaft.
– Place inner clutch hub and a new safety plate on the main shaft.
– Coat the thread of the main shaft with Loctite 243 and mount
hexagon nut.
– Fit clutch holder 583.29.003.000 and tighten hexagon nut to
90 Nm.
– Remove clutch holder.
– Check clutch hub and main shaft for smooth operation and axial
clearance.
– Secure outer clutch hub hexagon nut by bending the safety plate
up into place.
A
B
1
2
3