Mounting The Clutch Discs; Installing The Clutch Release Shaft - KTM 400-660 LC4 1998-2005 Repair Manual

6-9F
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Mounting the clutch discs

– Thoroughly oil the O-ring
– Oil the lining disc
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– Thoroughly oil all clutch discs before mounting.
– Alternately mount 1 steel disc and one lining disc.
NOTE: The last disc must be a lining disc.
M
– Grease the end of the push rod with Molykote grease and fit the
– When mounting the pressure cap make sure that bore
– Place the springs in the pressure cap and fit the HH srews with
– Secure carefully to 10 Nm in a diagonal pattern, to avoid any
NOTE:
– Use offset instead of flat spring retainers for 640 ccm engines.
– From model 2000 onwards spring retainers 6,5x20x2 replaced

Installing the clutch release shaft

– Oil needle bushings in engine housing.
– Insert the grooved ring
– Check for the right position of the circlip
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– Slide the release shaft into the housing until it lies on the clutch
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(internal diameter: 127 mm) and mount it,
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making sure that the disc encircles the O-ring (see illustration).
! CAUTION
OUNT ALL STEEL DISKS WITH THE SHARP EDGE FACING DOWNWARD
pressure cap together with the push rod.
pressure cap and the pin
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spring retainers.
damage to the inner clutch hub thread.
spring retainers 6,2x20x3,2, these can be used for all models with
540, 620 and 640 engines.
into the housing with the open side up.
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shaft.
push rod.
and put it onto the inner clutch hub.
!
of the inner clutch hub coincide.
on the clutch release
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.
in the
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