Assembly Of Engine Housing - KTM 400-660 LC4 1998-2005 Repair Manual

6-5E
SX, SXC
M6x30
SC
M6x30
LC4-E
M6x30/35
M6x30
640 LC4 2003 on
M6x55
M6x55
M6x65
M6X55
M6x65
M6x55
M6x95
M6x65
M6x30/35
M6x55
M6x30

Assembly of engine housing

– Make sure both dowels are in place in the left housing half, and put
gasket on the sealing surface. Use a little bit of grease to hold the
gasket in place.
– Grease all shaft seal rings in the left side of the housing.
– Oil all bearings in the right side of the housing and put on the
housing half. If necessary, tap lightly with a plastic mallet and turn
transmission shafts.
– Check to make sure that the gasket is in the proper position before
final assembly.
– Grease housing bolts (threads and contact surfaces of bolts heads).
Insert bolts and assemble the housing (see sketch for bolt lengths).
– Check all the shafts for smooth operation before and after tightening
with 7-8 Nm.
– Mount case in mounting rack and check function of gear-change by
engaging all gears.
– Check crankshaft axial clearance (0.03 - 0.12 mm) (0.0012 - 0.0047
in) and fit crankshaft locking bolt.
NOTE: On Adventure-models bolts M6x35 are used instead of the two
upper bolts M6x30.
NOTE: On Adventure-models bolts M6x35 are used instead of the two
upper bolts M6x30.