Checking The Clutch Components For Wear - KTM 400-660 LC4 1998-2005 Repair Manual

5-18E
9
From model 2003 on

Checking the clutch components for wear

Thrust bearing 1 – Check for signs of wear.
2
Push rod – Check the face side for signs of wear.
3
Clutch release shaft , sealing cup
6
Clutch pressure springs – Minimum length: 34.5 mm (1.36 in) (length/new spring: 37 mm (1.457 in)) / 660 SMC Minimum
length: 31.5 mm (1.26 in) (length/new spring: 33.5 mm (1.34 in)).
Replace all 6 springs if necessary.
7
Clutch discs – Clutch discs must be plane.
≠ 1.5 mm (0.066 in) must be free of grooves.
7 steel discs
8 lining discs ≠ 2.7 mm (0.106 in), wear limit: 2.5 mm (0.1 in)
8
Inner clutch hub – Check both the exterior and the interior toothing for signs of wear.
9
Needle bearing – Check for signs of wear.
bk
Outer clutch hub – Check if all rivets
bl
Absorbing elements
Power transmission from the primary drive to the clutch is cushioned by rubber elements
checked in the course of normal checking for signs of wear. It is recommended to check the elements while disassembling the
engine. Try to turn the outer clutch hub after removing the inner clutch hub (engine will lock). Dead travel should be impossible.
bo
Check O-ring for brittleness and cracks. If the cross section of the O-ring is oval (deformed) replace the O-ring.
13
11
10
3
4
5
4 5
and needle bearing
bm
are tight.
7
12
8
14
LOCTITE 243
2
– Check for damage and signs of wear.
1
6
bl
. These rubber elements must be