1998-2005 KTM 400-660 LC4 Paper Engine Repair Manual

Description

This 500 page printed and bound 1998-2005 KTM 400-660 LC4 Engine Repair Manual is an authorized reproduction of the original, out of print manual. It covers ONLY the engine on the following motorcycles:

1998, 1999, 2000, 2001, 2002, 2003, 3004, 2005 KTM 400-660 LC4

Table of Contents

General Information
Models Without Frame Oil
Changing The Engine Oil
Changing The Oil Filter
Changing The Microfilter
Oil Circuit
Oil Circuit 660 Smc (model 2003)
Models With Frame Oil
Changing The Engine Oil
Changing The Fine Screen Filter
Changing The Oil Filter
Oil Circuit
Oil Circuit 660 Smc (from Model 2004 On)
Secondary Air System
Epc-system
Special Tools Chassis
Special Tools Motor
Bleeding Of The Hydraulic Clutch

Removing And Installing The Engine
Removing The Engine
Refitting The Engine
Checking The Adjustment Of The Hand Decompression Cable

Dismantling The Engine
Drain Engine Oil
Removing The Electric Starter Motor
Removing The Clutch Release Lever And The Oil Hoses
Removing The Oil Filter
Removing The Epc Wiring Harness
Removing The Ignition (kokusan 4k-2)
Removing The Ignition (sem)
Removing The Ignition (kokusan 4k-3)
Removing The Electric Starter Drive
Removing The Cylinder Head Top Section
Blocking The Crankshaft
Removing The Camshaft And The Automatic Tensioner
Removing Cylinder Head
Removing Cylinder And Piston
Removing Engine Sprocket
Removing Clutch And Primary Drive
Removing The Oil Pumps
Removing The Timing Chain And The Timing Gear
Removing The Clutch Release Shaft
Parting Of Engine Housing
Removing The Shift Mechanism
Removing The Transmission Shafts
Removing The Kickstarter Shaft

Servicing On Individual Components
Working On The Right Housing Half
Working On The Left Housing Half
Crankshaft
Measuring And Adjusting Of Crankshaft Axial Play
Checking The Piston
Mounting Instructions For Piston Rings
Piston Ring End Gap
Measuring Piston And Cylinder, Determining
The Piston Fitting Clearance
Cylinder – Nikasil Coating
Recoated Cylinder
Disassembling The Cylinder Head And Checking
The Components For Wear
Disassembling The Cylinder Head Top Section And
Checking Components For Wear
Pre-assembling The Cylinder Head Top Section
Checking The Components Of The Timing Mechanism For Wear
Disassembling The Camshaft And Checking The
Components For Wear
Pre-assembling The Camshaft
Automatic Tensioner
Preassembly Of Automatic Tensioner
Disassembling The Oil Pumps And Checking The
Components For Wear
Oil Lines (sx, Sxc)
Oil Lines (sc)
Oil Lines (660 Smc Model 2003)
Oil Lines (models With Frame Oil)
Oil Lines (660 Smc From Model 2004 On)
Checking The Kickstarter Components For Wear
Preassembly Of Kickstarter Shaft
Clutch Cover
Replacing Absorbing Elements Of The Outer Clutch Hub
Checking The Clutch Components For Wear
Checking The Shift Mechanism Components For Wear
Preassembly Of Shift Shaft
Shift Mechanism Support
Balancer Shaft
Disassembling And Reassembling The Water Pump
Important Note Regards Working On Transmission
Assembling The Main Shaft
Assembling The Counter Shaft
Removing The Intermediate Gear
Checking The Freewheel
Replacing The Freewheel Hub
Electric Starter Motor
Checking Secondary Air System (sls)
Ignition (kokusan 4k-2)
Checking The Stator And The Pulse Generator (kokusan 4k-2)
Replacing The Stator (kokusan 4k-2)
Ignition (sem)
Checking The Stator (sem)
Replacing The Stator (sem)
Ignition (kokusan 4k-2)
Checking The Stator (kokusan 4k-3)
Replacing The Stator (kokusan 4k-3)
Mounting The Kickstarter Unit
Mounting Transmission And Shift Mechanism
Adjustment Of Return Spring
Pretensioning Of The Starter Spring
Mounting Crankshaft
Assembly Of Engine Housing
Mounting Oil Filter
Mounting The Engine Sprocket
Mounting The Timing Gear And The Timing Chain
Mounting The Oil Pumps
Mounting The Balancer Shaft And The Primary Pinion
Mounting The Clutch
Mounting The Clutch Discs
Installing The Clutch Release Shaft
Adjusting The Clutch Release
Measure Dimension €žy
Mounting Piston And Cylinder
Mounting The Cylinder Head
Mounting The Camshaft, Timing Marks
Mounting The Water Pump
Mounting The Cylinder Head Top Section
Mounting The Automatic Tensioner
Automatic Decompression Testing
Adjustment Of Valve Clearance
Mounting The Clutch Cover
Mounting The Electric Starter Drive
Mounting The Ignition (kokusan)
Adjusting The Pulse Generator
Mounting The Ignition (sem)
Adjustment Of Ignition Point (sem)
Mounting The Epc Wiring Harness
Mounting The Ignition (kokusan 4k-3)
Adjustment Of Ignition Point (kokusan 4k-3)
Mounting The Oil Hoses
Mounting The Clutch Release Lever
Mounting The Electric Starter Motor
Mounting The Water Hoses
Pouring In Engine Oil
Mounting The Kickstarter And The Shift Lever

Electrical
Electrical – Super Competition
Checking The Voltage Regulator-rectifier
Checking The Voltage Regulator
Checking The Capacitor
Electrical – Lc4 Competition
Charging System
Leakage Inspection
Removing The Battery
Charging The Battery
Charging Voltage / Checking The Voltage Regulator
Checking The Capacitor
Checking The Neutral Switch
Electrical – Lc4
Charging System
Leakage Inspection
Removing The Battery
Charging The Battery
Charging Voltage / Checking The Voltage Regulator
Checking The Capacitor
Electric Starter System
Checking The Start Auxiliary Relay
Checking The Auxiliary Starting Relay For Faultless Operation
Checking The Diode
Checking The Starter Relay
Checking The Electric Starter Motor
Checking The Clutch Switch
Checking The Emergency Off Switch
Trouble Shooting In The Electric Starter Sytem
Ignition System
Cdi Unit
Checking The Ignition Coil
Trouble Shooting In The Ignition System
Epc System
Dismount / Renew Solenoid Valve For Epc
Check Of Solenoid Valve For Epc
Controller Of The Epc System
Check Of Epc System Microswitch
Replacing The Epc System Microswitch
Check Of Idle Switch / Contact Screws
Electrical – Duke-e
Charging System
Leakage Inspection
Charging Voltage / Checking The Voltage Regulator
Removing The Battery
Charging The Battery
Checking The Capacitor
Electric Starter System
Checking The Start Auxiliary Relay
Checking The Auxiliary Starting Relay For Faultless Operation
Checking The Diodes
Checking The Clutch Switch
Checking The Emergency Off Switch
Checking The Starter Relay
Checking The Electric Starter Motor
Trouble Shooting In The Electric Starter Sytem
Idle Switch
Ignition System
Cdi Unit
Checking The Ignition Coil
Spark Plug Connector
Checking The Side Stand Relay
Checking The Side Stand Switch
Trouble Shooting In The Ignition System
Electrical – Sxc ’99
Checking The Voltage Regulator
Checking The Capacitor
Electrical – Sc ’99
Checking The Voltage Regulator
Checking The Capacitor
Checking The Ignition Coil
Electrical – Duke ’99
Charging System
Leakage Inspection
Charging Voltage / Checking The Voltage Regulator
Removing The Battery
Charging The Battery
Checking The Capacitor
Electric Starter System
Checking The Start Auxiliary Relay
Checking The Auxiliary Starting Relay For Faultless Operation
Checking The Diodes
Checking The Clutch Switch
Checking The Emergency Off Switch
Checking The Starter Relay
Checking The Electric Starter Motor
Trouble Shooting In The Electric Starter Sytem
Checking The Idle Switch
Ignition System
Cdi Unit
Checking The Ignition Coil
Spark Plug Connector
Checking The Side Stand Relay
Checking The Side Stand Switch
Trouble Shooting In The Ignition System
Measurements With Peak Voltage Adapter
(from Model 2000 On)
Dynamic Generator Values 400/640 Lc4-e, 625 Sxc, Duke, Adventure
Static Ignition Values 400/640 Lc4-e, 625 Sxc, Duke, Adventure
Static Generator Values 400/640 Lc4-e, 625 Sxc, Duke, Adventure
Static Ignition Values 400/620/625 Sc, 660 Smc
Static Generator Values 400/620/625 Sc, 660 Smc
Checking Speedometer And Speedometer Sensor

Fuel System
Mikuni Bst 40
Part-load System
Full-load System
Disassembling The Carburetor
Assembling The Carburetor
Checking/adjusting The Throttle Sensor
Adjust Idling Speed
Adjusting The Throttle Cable
Check Float Level
Dell’orto
Disassembling The Carburetor (dell’orto Phm 40 Sd)
Assembling The Carburetor (dell’orto Phm 40 Sd)
Disassembling The Carburetor (dell’orto Phm 38 Nd)
Assembling The Carburetor (dell’orto Phm 38 Nd)
Disassembling The Carburetor (dell’orto Vhsb 38 Qs)
Assembling The Carburetor (dell’orto Vhsb 38 Qs)
Check Float Level (dell’orto 38 Nd / 40 Sd)
Checking Axial Clearance Of Float (dell’orto 38 Nd / 40 Sd)
Adjust Hot Start Device (dell’orto 40 Sd)
Adjusting The Throttle Cable
Adjusting The Choke Cable
Keihin Fcr 41
Disassembling The Carburetor
Checking The Choke Slide
Checking The Accelerator Pump
Checking The Jet Needle
Checking The Float Needle Valve
Checking The Throttle Valve
Assembling The Carburetor
Adjusting The Position Of The Throttle Valve Sensor
Checking The Throttle Valve Sensor
Dismounting And Installing The Throttle Valve Sensor
Adjust Idling Speed
Checking/adjusting The Float Height
Keihin Fcr-mx 41
Disassembling The Carburetor
Checking The Choke Slide
Checking The Accelerator Pump
Checking The Jet Needle
Checking The Float Needle Valve
Checking The Throttle Valve
Assembling The Carburetor
Adjusting The Position Of The Throttle Valve Sensor
Checking The Throttle Valve Sensor
Dismounting And Installing The Throttle Valve Sensor
Adjust Idling Speed
Checking/adjusting The Float Height

Troubleshooting
Trouble Shooting (sxt Sxc Sc Smc) ___
Trouble Shooting (lc4 Competition)
Trouble Shooting (lc4)

Chassis
Dismounting/mounting The Chassis Components
Dismounting/mounting The Rocker Arm And Shock Absorber
Dismounting/mounting The Fork Legs
Dismounting/mounting The Swing Arm
Overhauung The Chassis Components
Replacing The Swing Arm Support
Replacing The Steering Head Bearing
Replacing The Chain, Rear Sprockets And Chain Guides
Replacing The Front Wheel Bearings
Replacing The Rear Wheel Bearings
Overhauling The Rocker Arm
Replacing The Linkage Bolt Bearing In The Frame
Cutting And Riveting The Chain (from Model 2005 On)

Technical Specifications
Model 1998
Engine 400/540 Sxc
Chassis 400/540 Sxc
Engine 400/620 Sx Sc
Chassis 400/620 Sx, Sc
Engine 620 Lc4 Competition
Chassis 620 Lc4 Competition
Engine 400/540 Sxc
Chassis 400/640 Lc4
Chassis 640 Adventure-r
Chassis 640 Duke-e

Model 1999
Engine 400/540 Sxc 620 Sx
Chassis 400/540 Sxc 620 Sx
Engine 400/620 Sc
Chassis 400/620 Sc
Engine 620 Lc4 Competition
Chassis 620 Lc4 Competition
Engine 400/640 Lc4
Chassis 400/640 Lc4
Engine 640 Adventure-r
Chassis 640 Adventure-r
Engine 640 Duke
Chassis 640 Duke

Model 2000
Engine Sc, Supermoto
Chassis Sc, Supermoto
Engine Lc4-e, Adventure, Duke
Chassis Lc4-e Supermoto
Chassis 640 Adventure-r
Chassis 640 Duke
Chassis 640 Duke Aus
Engine 400 Sxc
Chassis 400/540 Sxc

Model 2001
Engine 620 Sc, Supermoto
Chassis 620 Sc, Supermoto
Engine Lc4-e, Adventure, Duke
Chassis Lc4-e, Supermoto
Chassis 640 Lc4 Adventure
Chassis 640 Duke
Chassis 640 Duke Usa, Aus

Model 2002
Engine 625 Sc, Supermoto
Chassis 625 Sc, Supermoto
Engine 640 Lc4, Adventure, Duke
Chassis 640 Lc4, Supermoto
Chassis 640 Adventure
Chassis 640 Duke

Model 2003
Engine 625 Sxc
Chassis 625 Sxc
Engine 640 Lc4, Adventure, Duke
Chassis 640 Lc4, Supermoto
Chassis 640 Lc4 Adventure
Chassis 640 Duke
Engine 660 Smc
Chassis 660 Smc

Model 2004
Engine 625 Sxc Usa
Engine 625 Sxc Eur
Chassis 625 Sxc
Engine 640 Lc4, Adventure, Duke
Chassis 640 Lc4, Supermoto
Chassis 640 Lc4 Adventure
Chassis 640 Duke
Engine 660 Smc
Chassis 660 Smc

Model 2005
Engine 625 Sxc/smc
Chassis 625 Sxc/smc
Engine 640 Lc4, Adventure, Duke
Chassis 640 Lc4, Supermoto
Chassis 640 Adventure
Chassis 640 Duke
Engine 660 Smc
Chassis 660 Smc

Tightening Torques
Engine
Chassis
Assembly Clearance, Wear Limit

Periodic Maintenance Schedule

Wiring Diagrams