Disassembling The Engine - KTM 400-660 LC4 1998-2005 Repair Manual

4-1E
4

DISASSEMBLING THE ENGINE

INDEX
DRAIN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES . . . . . . .4-3
REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . .4-6
REMOVING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . . . .4-7
BLOCKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER . . . . . .4-8
REMOVING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . .4-11
REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
REMOVING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . . . .4-14
REMOVING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . .4-14
PARTING OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
REMOVING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
REMOVING THE TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . .4-17
REMOVING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .4-17