Adjustment Of Valve Clearance; Mounting The Clutch Cover - KTM 400-660 LC4 1998-2005 Repair Manual

6-15F
A
2

Adjustment of valve clearance

– Adjust piston to ignition top dead center (check marks of flywheel)
and screw crankshaft locking bolt back in.
I
F THE PISTON IS NOT IN IGNITION
ADJUSTMENT IS NOT POSSIBLE
FULL TURN
– Valve clearance
and adjusting screw.
VALVE CLEARANCE 400 : INTAKE 0.20 mm / EXHAUST 0.20 mm
VALVE CLEARANCE 540 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 620 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 625 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 640 : INTAKE 0.15 mm / EXHAUST 0.15 mm
VALVE CLEARANCE 660 : INTAKE 0.15 mm / EXHAUST 0.15 mm
– Tighten counternuts with 16 Nm.
– Remove the crankshaft locking bolt.
– Mount both valve covers with new gaskets and bolts with copper
seal rings.
– Tighten bolts with 8 Nm.
– Insert and tighten spark plug with 20 Nm.

Mounting the clutch cover

– Pour approx. 30 ml of oil into the crankshaft journal hole.
– Make sure that the two dowels are mounted.
– Fit new gasket and fix with dabs of grease.
1
– Apply grease to the shaft seal ring in the clutch cover and mount
clutch cover.
2
– Fit bolts and bump rubber
NOTE: Bolts
– Tighten bolts with 8 Nm.
! CAUTION
TDC,
-
IN THAT CASE CRANKSHAFT MUST BE MOVED A
.
is measured at cold engine between valve stem
A
for kickstarter.
1
must each be provided with a copper seal ring.
2
!
VALVES ARE OPENED AND A CORRECT