Checking The Kickstarter Components For Wear; Preassembly Of Kickstarter Shaft; Clutch Cover; Replacing Absorbing Elements Of The Outer Clutch Hub - KTM 400-660 LC4 1998-2005 Repair Manual

9
5
7
8
4
3
A
B
10
13
C

Checking the kickstarter components for wear

Starter gear
Check the bearing for clearance (the starter gear must be in permanent
mesh with the outer clutch hub).
Intermediate starter gear
Check the bearing for clearance.
6
Kick starter shaft
Check the toothing for signs of wear.
1
Ratchet gear
Check the ascending surface and the toothing for signs of wear.
2
Stop bolt
Check for signs of wear.
Replace the seal ring
NOTE: Due to a parts change from 2000 onwards the seal ring is
A
blue-green and is to be mounted with the seal lip to the outer side.

Preassembly of kickstarter shaft

– Clamp kickstarter shaft with toothed end in vice (use soft jaw-
– Mount circlip
B
– Fit spring guide
– Remove kickstarter shaft from vice and fit ratchet gear spring.
– Mount the ratchet gear

Clutch cover

Balancer shaft bearing
Use the bearing extractor tool 151.12.017.000 with insert to remove
the grooved ball bearing from the bearing seat.
Insert the new bearing into the seat and ensure flush fit.
Seal ring
Use a screwdriver to lever the old shaft seal ring out of the clutch cover.
Insert the new shaft seal ring and ensure flush fit.
11

Replacing absorbing elements of the outer clutch hub

14
– Drill open the clutch rivets
NOTE: When performing repair work always exchange all 8 absorbing
elements.
T
HE DAMPING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN
ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED
DIRECTLY ON THE PRIMARY GEAR CROWN
12
UNDER TENSION WITH THE CLUTCH RIVETTING TOOL
– Apply the special tool 546.29.027.000 as shown, screw together and
1
2
3
4
5
6
covers).
7
in lower ring groove.
8
with collar facing downwards and circlip
sharp edge facing upwards.
4
on the kickstarter shaft in such a way that
A B
the markings and coincide.
bk
bl
bm
take off the parts.
!
CAUTION
lock the rivets with a pointed mandrel and a round mandrel.
Locking pressure for the pointed mandrel: approx. 4000 kg
Locking pressure for the round mandrel: approx. 5000 kg
in area of the retaining bracket
!
,
THE PARTS MUST BE HELD IN POSITION
C
BEFORE RIVETTING
5-17E
9
with
bn
and
bo
. T
O
.