Servicing On Individual Components - KTM 400-660 LC4 1998-2005 Repair Manual

5-1E
5

SERVICING ON INDIVIDUAL COMPONENTS

INDEX
WORKING ON THE RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . .5-3
WORKING ON THE LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . .5-5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY . . . . . . . . .5-7
CHECKING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
MOUNTING INSTRUCTIONS FOR PISTON RINGS . . . . . . . . . . . . . . . . . . .5-8
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
MEASURING PISTON AND CYLINDER, DETERMINING
THE PISTON FITTING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
CYLINDER – NIKASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
DISASSEMBLING THE CYLINDER HEAD AND CHECKING
THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND
CHECKING COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . .5-11
PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . .5-11
CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR . . .5-12
DISASSEMBLING THE CAMSHAFT AND CHECKING THE
COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
PRE-ASSEMBLING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
PREASSEMBLY OF AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . .5-13
DISASSEMBLING THE OIL PUMPS AND CHECKING THE
COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
OIL LINES (SX, SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
OIL LINES (SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
OIL LINES (660 SMC MODEL 2003) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
OIL LINES (MODELS WITH FRAME OIL) . . . . . . . . . . . . . . . . . . . . . . . . .5-15
OIL LINES (660 SMC FROM MODEL 2004 ON) . . . . . . . . . . . . . . . . . . .5-16
CHECKING THE KICKSTARTER COMPONENTS FOR WEAR . . . . . . . . . . .5-17
PREASSEMBLY OF KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .5-17
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB . . . .5-17