Adjusting The Clutch Release; Measure The Dimension „Y" (From Model 2003 On); Mounting Piston And Cylinder; Push Rod - KTM 400-660 LC4 1998-2005 Repair Manual

P P A A R R A A L L L L E E L L
Sealing surface of the clutch
slave cylinder
push
rod
– Turn the release shaft clockwise until it glides a bit further into the
housing. The push rod now sits on the release shaft.
– Apply Loctite 243 to the bolt (s).
– Fasten the retaining bracket for the clutch release
1

Adjusting the clutch release

– Turn the clutch release shaft clockwise to stop.
– The slot on the front side of the release shaft should now be parallel
to the sealing surface of the housing (see ill.).
– To adjust the clutch release remove pin
with a screwdriver until the desired setting is achieved.
– Once you have completed the adjustment, the push rod is to be
3
secured with a pin.
T
O MAKE SURE THAT THE CLUTCH DISENGAGES PERFECTLY
MUST BE PROPERLY ADJUSTED
2
Measure the dimension „Y" (from model 2003 on)
NOTE: The dimension „Y" must be adjusted to make sure the clutch
release operates correctly.
The dimension „Y" is the distance between the sealing area of the
clutch slave cylinder and the pushrod.
– Oil the pushrod and insert in the main shaft all the way in to the
stop.
– Measure the distance between the mounting face (without the
gasket) of the clutch slave cylinder to the pushrod using a depth
gauge.
– To adjust, remove the splint
screwdriver.
– After making the adjustment, lock the pushrod with the splint again.

Mounting piston and cylinder

– Lubricate the piston pin eye in the connecting rod and the piston pin
with oil.
– Mount piston and secure piston pin with 2 new wire circlips.
T
HE ARROW ON THE PISTON HEAD MUST POINT IN THE DIRECTION OF TRAVEL
M
OUNT WIRE CIRCLIPS IN
!
CAUTION
.
2
and turn the pushrod
Dimension „Y" = 2.75 mm
Dimension „Y" from model 2004 on = 1.7 mm
!
CAUTION
„6 ' " „12
O CLOCK OR
12 o'clock-pos.
6-10E
1
with bolt(s).
2 3
and turn the push rod
!
,
THE CLUTCH RELEASE
3
with a
!
.
' " ( .).
O CLOCK POSITION SEE ILL
6 o'clock-pos.