Shift Mechanism Support; Balancer Shaft; Disassembling And Reassembling The Water Pump - KTM 400-660 LC4 1998-2005 Repair Manual

5-20E
2
3
5
10
9
6
8
11

Shift mechanism support

– If the grooved ball bearing
1
T
O PREVENT DAMAGING OF THE SHIFT MECHANISM SUPPORT
EXCESSIVE FORCE WHEN INSERTING THE GROOVED BALL BEARINGS
– Apply Loctite 243 to the screw and fix the bearing.
– The new needle bearing of the kickstarter shaft

Balancer shaft

Check bearing seat
A
Check three allan head bolts

Disassembling and reassembling the water pump

Remove the water pump cover
– Remove circlip
– If grooved ball bearings
– Properly lubricate new grooved ball bearings and press in to stop
4
7
– Mount circlip
– Cover new shaft seal ring with Loctite 648 and press in with the
– Lubricate water pump shaft and mount carefully so as to not
– Mount circlip
– Finally, remove silicone from the sealing flange and mount 2 new
press the new grooved ball bearing all the way into the seat.
!
CAUTION
in flush.
A
for wear and tear.
3
5
from the water pump shaft
7
water pump wheel out of the grooved ball bearings.
8
bk
seal ring and press out bearing.
with the open sides facing each to them.
9
.
printing facing outward.
damage sealing lips of shaft seal ring and check for smooth working.
5
and water pump cover
bl
O-rings .
1
of the shift roller must be exchanged,
,
DO NOT APPLY
.
2
has to be pressed
for tight fit.
4
together with the gasket.
6
and pull shaft and
are replaced, remove circlip
4
with gasket.
!
9
and shaft