Disassembling The Cylinder Head Top Section And Checking The Components For Wear; Pre-Assembling The Cylinder Head Top Section - KTM 400-660 LC4 1998-2005 Repair Manual

15
15
12
3
1
2
14
13
10
6
4
7
5
8
13
Disassembling the cylinder head top section and checking
the components for wear
– Simply pull the rocker arm axles
Undo bolt
the following components:
– Press the decompression shaft
1
– Clean all components.
2
Rocker arm shafts
3
The rocker arm shafts must be free of grooves and should turn easily
within the rocker arms
12
14
13
Rocker arm rollers
The rocker arm rollers must move smoothly. Rocker arm rollers must be
removed in the case of radial clearance.
Adjusting screws
The contact surfaces of the adjusting screws must be plane.
Decompression shaft
Check for smooth operation and clearance in the bearing bore.
9
11
10

Pre-assembling the cylinder head top section

– Insert decompression shaft
– Mount the new O-ring
– Mount the decompression shaft lever
– Apply Loctite 243 to the thread of bolt
– Hook the decompression lever spring onto the decompression shaft
T
BOLT
SLIGHTLY PRESSED AGAINST THE TOP SECTION BY THE COVER DISC
THE PRESSURE ON THE
DECOMPRESSION
COMPENSATION WASHERS
NOTE: Discs
– Mount new O-rings
– Mount rocker arms
– On the side of the water pump one thrust washer
– The axial play on the opposite side is roughly equalized with thrust
The axial clearance of the rocker arm axles must be 0.20 - 0.30 mm.
section. Then take both rocker arms
3 bn
and out of the cylinder head top section.
4
and remove
cylinder head top section together with the washers
1
2
.
bm
bo
bk
top section.
8
7
the cover disc in such a way that the O-ring fits into the recess of
the cover disc.
together with washer 5 .
lever.
!
CAUTION
HE DECOMPRESSION SHAFT MUST EXHIBIT NO AXIAL PLAY WHEN THE ALLAN HEAD
4
. T
IS TIGHTENED O ENSURE THAT THE O
O-
RING MUST NOT BE EXCESSIVELY HIGH AS THE
SHAFT WILL
bl
IF NECESSARY
bl
are available 0.15 mm, 0.30 mm and 0.50 mm thick.
bp
on rocker arm shafts
2
, thrust washers
in) must be mounted.
≠ 1.0 (0.04 in) and ≠ 0.5 mm (0.02 in).
3
washers
1
out of the cylinder head top
2
together with thrust washers
5
Washer
Decompression shaft lever
7
Covering disc
8
O-ring
Decompression lever spring
bk
inwards and take it out of the
bl .
bk
with compensation washers
, the decompression lever spring
6
.
4
and mount the bolt
8
- f
RING ORMS A SEAL
. A
BECOME SLUGGISH DJUST
.
1
.
3
and rocker arm shafts
≠ 1.0 mm (0.04
bn
5-11E
6
9
bl
into the
9
and
!
,
IT MUST BE
7
. H ,
OWEVER
OUT WITH
1
.