Mounting The Balancer Shaft And The Primary Pinion; Mounting The Clutch - KTM 400-660 LC4 1998-2005 Repair Manual

A
2
3

Mounting the balancer shaft and the primary pinion

– Fit balancer shaft in the bearing.
– Mount woodruff key in crankshaft and place primary pinion on the
crankshaft. When doing so, adjust the teeth of the primary pinion
B
and the balancer shaft in such a way that the markings
coincide.
– Apply Loctite 243 to the crankshaft thread.
– Mount spring ring and hexagon nut and tighten hexagon nut to 170
Nm.
I
F THE BALANCER SHAFT IS NOT INSTALLED ALSO REMOVE BOTH GROOVED BALL
BEARINGS
GROOVED BALL BEARINGS WOULD DROP OUT OF THE BEARING SEATS AND CAUSE
ENGINE DAMAGE AS SOON AS THE ENGINE HEATS UP

Mounting the clutch

1
– Fit kickstarter intermediate gear
clearance space towards housing.
– Slide the inner ring and the needle bearing
– Fit outer clutch hub and outer stop disc
– Degrease the thread of the main shaft.
– Place inner clutch hub and a new safety plate on the main shaft.
– Coat the thread of the main shaft with Loctite 243 and mount
hexagon nut.
– Fit clutch holder 583.29.003.000 and tighten hexagon nut to
90 Nm.
– Remove clutch holder.
– Check clutch hub and main shaft for smooth operation and axial
clearance.
– Secure outer clutch hub hexagon nut by bending the safety plate
up into place.
! CAUTION
(
IN THE CLUTCH COVER AND IN THE ENGINE HOUSING
6-8F
and
A
!
). O
THERWISE THE
.
onto counter shaft with
1
onto the main shaft.
2
(22.2x35x3 mm).
3
B