KTM LC4 400-660LC42003 engine. Manual - part 4

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

4-4D

– Undo 6 bolts and remove starter flange incl. gasket.

– Insert the holding spanner 

2

into the 2 bores of the flywheel.

– Hold the flywheel and remove the hexagon nut (LH thread).
– Remove the disc.

! 

CAUTION

!

T

O AVOID DISTORTION OF THE CRANK WEB

, 

NEVER MOUNT THE CRANKSHAFT

LOCKING BOLT TO STEADY THE FLYWHEEL

.

– Put the protection cover 

1

onto the crankshaft and mount the

flywheel extractor.

– Pull off the flywheel and take the woodruff key out of the

crankshaft.

! 

CAUTION

!

N

EVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID

LOOSENING OF THE MAGNETS

.

1

2

4-5D

Removing the ignition (SEM)

– Undo the 4 bolts and remove ignition cover and O-ring.
– Use the crankshaft locking bolt to block the crankshaft.

– Unscrew collar nut (LH thread) and remove spring disc.
– Fit extractor and pull off flywheel. Use protective sleeve.
– Remove woodruff key from the crankshaft.
– Twist the crankshaft locking bolt out until the crankshaft is no longer

blocked.

! 

CAUTION

!

N

EVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID

LOOSENING OF THE MAGNETS

.

Removing the ignition (Kokusan 4K-3)

– Undo the 4 bolts and take off the ignition cover together with the

O-ring.

– Use the crankshaft locking bolt to block the crankshaft.

– Undo the collar nut (LH thread) and remove the spring washer.

– Mount the extractor and pull off the flywheel.
– Take the woodruff key out of the crankshaft.
– Finally, twist out the crankshaft locking bolt until the crankshaft is no

longer blocked.

! 

CAUTION

!

N

EVER USE A HAMMER OR SIMILAR TOOL ON THE FLYWHEEL TO PREVENT

LOOSENING OF THE MAGNETS

.

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Removing the electric starter drive

– Pull the reduction gear 

1

off the bearing bolt.

– Remove both needle bearings 

2

and pull the bearing bolt 

3

out of

the engine housing.

– Remove the freewheel gear 

4

and the needle bearing 

5

.

4-6D

1

2

3

4

5

4-7D

Removing the cylinder head top section

– Unscrew plug 

1

with gasket and remove pressure spring from

automatic tensioner. 

– Undo the 4 hose clamps and remove both hoses (

2

and 

3

).

– Remove all 6 bolts 

4

together with the seal rings and take off both

valve covers together with the gaskets.

– Remove the hexagon nut 

5

and take off the retaining bracket of the

solenoid valve 

6

.

NOTE: A retaining bracket is only used in engines with EPC.

– Remove all 11 bolts. Then remove the cylinder head top section.

! 

CAUTION

!

W

HEN REMOVING CYLINDER HEAD TOP SECTION DO NOT CHOCK IT

. T

HIS WOULD

DAMAGE THE HOUSING OF THE WATER PUMP

.

NOTE: The control valve of SLS models can be removed after undoing
the bolts of the cylinder head top section.

1

2

3

4

5

6

4-8D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

– Pull water pump upward and simultaneously turn crankshaft.

NOTE: When groove 

A

in the HH bolt is vertical, the water pump can

be pulled upward and taken out of the cylinder head without the 
application of force.

Blocking the crankshaft

– Turn the piston to position TDC (mark 

B

must coincide with the

plane surface of the cylinder head).

– Undo the crankshaft locking bolt 

1

.

– Remove the copper disc 

2

.

NOTE: Same engines are equipped with a normal bolt M8x16 and a
copper washer 8x12x1 instead of the crankshaft locking bolt M8 and a
copper washer 8x14x3. In this case the special tool 580.30.080.000
must be used.

– Reinsert crankshaft locking bolt by hand.
– If the bolt does not slide smoothly into its bore, slightly move the

camshaft gear (if cylinder head top section is mounted turn the
flywheel) back and forth until the crankshaft locking bolt engages in
its bore.

– Tighten crankshaft locking bolt with 20 Nm.

! 

CAUTION

!

U

NDER NO CIRCUMSTANCES APPLY FORCE TO

bolt

IN CRANKSHAFT LOCKING BOLT

AS THIS WILL DAMAGE THE CRANKSHAFT

.

Removing the camshaft and the automatic tensioner

– Remove the driving bolt 

3

together with the two washers.

– Remove the two bolt 

4

and take off the automatic tensioner 

5

and

the clamp 

6

.

A

B

1

2

4

3

5

6

4-9D

– Using a screwdriver, lever circlip 

1

out of the groove.

– Tilt camshaft and remove needle bushing 

2

.

– While tilted, pull camshaft from camshaft gear and remove together

with grooved ball bearing and circlip.

– Take the camshaft gear out of the timing chain as indicated in the

illustration.

1

2

4-10D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Removing cylinder head

– Unscrew chain guide bolt 

1

incl. gasket, bolts 

2

and collar nuts 

3

.

– Unscrew the 4 collar bolts 

4

and detach cylinder head with gasket.

Removing cylinder and piston

– Unscrew the 4 collar nuts at the cylinder base 

5

.

– Remove cylinder and cylinder base gasket.

– When working on an engine with a microfilter, remove the AH bolt

6

before taking off the cylinder.

– Disconnect the oil hose at the clutch cover and remove the

microfilter together with the holder.

6

1

3

4

5

2

4-11D

– Remove two wire circlips and press piston pin out of piston.
– Remove piston.

Removing engine sprocket

– Remove collar bolt 

1

and spring washer.

– Remove the sprocket from the counteshaft.
– Remove the distance bushing from the countershaft.

NOTE: If the gear-box and the clutch of the engine are in good
condition, throw it into gear in order to block the take-off shaft
(frictional connection to the blocked crankshaft is present). If the take-
off shaft cannot be blocked as described above, a chain sprocket holder
must be applied for the removal of the chain sprocket nut.

Removing clutch and primary drive

– Remove the 11 bolts and detach clutch cover with gasket.

– Unscrew the bolts 

3

of the clutch crosswise to prevent the clutch

discs from jamming when the springs are relieved of tension.

– Remove bolts, spring retainer and springs.
– Remove pressure cap with push rod.

– Remove the disc package and take the O-ring 

2

also off the inner

clutch hub.

2

1

3