KTM 400-660 LC4 1998-2005, Repair Manual

Page: 98 / 501

6-11E
– Cut off the section of the housing gasket protruding around the
cylinder flange and mount 2 dowels.
– Apply sealing compound to the sections near the chain tunnel and
mount the cylinder base gasket.
NOTE:
– To facilitate the installation of the cylinder it is recommended to
place a rubber band (see illustration) around the timing chain guide
and the timing chain tensioner.
– Oil the piston, adjust the piston rings (piston rings must be turned
120 ° against each other) and mount the piston mounting ring.
– Only for 640 LC4 engines a black cylinder base gasket (0,7 mm
thickness) is used, the other LC4 engines need the green gasket
(0,5mm thickness).
– Slide the cylinder over the piston and remove the mounting ring.
!
CAUTION
!
A
PPLY PARTICULAR CARE WHEN MOUNTING THE CYLINDER
! T
HE OIL SCRAPER RING
IS EXTREMELY FRAGILE
.
– Hook in the preassembled microfilter with the holding device onto
the rear studs and mount the collar nuts
1
at the cylinder base.
– Tighten collar nuts with 40 Nm crosswise.
– Then mount the bracket
2
and attach the microfilter.
NOTE: The upper edge of the piston is higher than the upper edge of
the cylinder when the cylinder is screwed down.
Mounting the cylinder head
– Check both dowels within the cylinder for proper fit.
– Mount cylinder head gasket and fit cylinder head.
– Oil the 4 bolt (threads and contact surfaces of bolt head) and then
mount with new copper seal rings.
NOTE: To be able to increase the tightening torque, copper seal rings
will replace the steel washers starting with the 2004 model.
– Tighten the collar screws crosswise in 2 stages up to the specified
torque of 50 Nm (53 Nm starting with the 2004 model). Tighten the
collar screws to 10 Nm during the first stage.
– Mount M8 collar nuts 3 on the front and rear side of cylinder and
tighten.
– Mount and tighten bolts
4
.
– Put a new seal ring on the chain guide bolt
5
and degrease the
thread.
– Apply Loctite 243 to the thread of the chain guide bolt, mount and
tighten it (30 Nm).
!
CAUTION
!
B
EFORE MOUNTING THE CHAIN GUIDE BOLT MAKE SURE THAT THE OPENING OF THE
TIMING CHAIN GUIDE IS VISIBLE THROUGH THE THREADED HOLE
. I
F THIS IS THE CASE
THE CHAIN GUIDE BOLT CAN EASILY BE MOUNTED WITHOUT EXERTING EXCESSIVE
FORCE
.
1
2
3
4
5