Adjustment Of Return Spring; Pretensioning Of The Starter Spring; Mounting Crankshaft - KTM 400-660 LC4 1998-2005 Repair Manual

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5

Adjustment of return spring

– Engage second or third gear.
– Check free travel of slide plate and check shift pin play.
– The free travel of the slide plate is the path this component travels
until the shift roller is moved. The return spring pressure will be felt.
Proceeding from the basic position, this free travel
identical for upward and downward movement.
– If necessary, the free travel must be readjusted by adjusting the
return spring.
– For this purpose, remove the shift shaft and bend the return spring
by an appropriate amount at points
shift shaft. After the shifting shaft has been fitted, the return spring
must rest against shift pin
shift mechanism support.
– If necessary, bend the return spring accordingly.

Pretensioning of the starter spring

– Fit kickstarter onto kickstarter shaft, turn one revolution in starting
direction and hold in this position.
2
– Mount the stop bolt together with a new seal ring and tighten it
manually.
!
I
T MUST BE POSSIBLE TO MOUNT THE STOP BOLT WITHOUT APPLYING EXCESSIVE
. I
FORCE F IT IS NOT POSSIBLE TO MOUNT THE STOP BOLT MANUALLY
KICKSTARTER SHAFT FURTHER AGAINST THE FORCE OF THE SPRING UNTIL THE STOP
.
BOLT CAN BE MOUNTED
– Move kickstarter to stop and remove.
2
– Tighten stop bolt with 50 Nm.
3
– Place O-ring (22x1 mm) and inner ring
counter shaft with the collar facing the gear.
5
– Mount stop disc (20.2x35x1 mm) onto the main shaft.

Mounting crankshaft

– Grease the shaft seal ring of the crankshaft and thoroughly oil the
roller bearing of the crankshaft.
– Fit mounting sleeve onto crankshaft and place crankshaft into
bearing.
B
using a pair of pliers. Refit
1
and against the centering cup on the
CAUTION
4
of roller bearing on the
6-4E
A should be
!
,
TURN THE