Mount The Timing Gear And The Timing Chain; Mounting The Oil Pumps - KTM 400-660 LC4 1998-2005 Repair Manual

6-7E
1
2
9

Mount the timing gear and the timing chain

– Insert woodruff key for timing gear into crankshaft and fit timing
gear onto crankshaft with high collar towards housing.
– Fit timing chain onto timing gear and draw up through chain tunnel.
– Insert the timing chain guide
3
bolt
– Apply Loctite 243 to the thread of the flat-head screw
– Fasten timing chain tensioner
– Check timing chain tensioner for smooth operation.
4
– Insert the safety device
6
6
5

Mounting the oil pumps

– Clean the sealing surfaces and install the oil pumps in the engine
7
housing (
– Degrease the threads and use Loctite 243 to secure the bolts in their
position.
8
– Degrease the threads of both bolts
the retaining bracket
A
– Put the stop discs (8.1x15x0.5 mm) onto the oil pump shafts.
– Insert the bearing needles into the oil pump shafts and slide on the
oil pump gears (high collars must face the casing; the small oil pump
gear must face the upper oil pump).
NOTE: From model 2002 onwards both oil pumps are fitted with the
same size of oil pump gear.
– Put on the upper stop discs
locking discs
10
1
2
and mount.
3
5
, apply Loctite 243 to the Allen head bolt
and mount.
A
M6x25!)
8
.
bk
.
, apply Loctite 243 to the Allen head
4
.
with flat head screw.
7
, apply Loctite 243 and mount
9
(8.1x15x0.5 mm) and mount the