KTM LC4 400-660LC42003 engine. Manual - part 11

6-17D

Adjusting the pulse generator

– Turn the flywheel until the elevated section of the flywheel 

1

coincides with the pulse generator 

2

.

– Use a feeler gauge to measure the distance between the pulse

generator and the flywheel.

Setpoint value: 0.75 mm (0.03 in) +/- 0.2 mm (0.008 in)

– If necessary undo the two bolts 

3

and adjust the distance by

moving the pulse generator. When mounting the two bolts secure
them with Loctite 243.

– Insert 2 dowels.
– Apply silicone to both sealing surfaces and mount a new gasket.
– Mount ignition cover and tighten all bolts.

– Insert a new O-ring 

4

into the groove of the starter cover and

fasten the starter cover with 3 bolts.

Mounting the ignition (SEM)

– Block crankshaft with crankshaft locking bolt. 
– Place woodruff key in crankshaft.
– Clean cones of crankshaft and flywheel and mount flywheel.
– Fit spring washer and collar nut.
– Tighten collar nut to 60 Nm.
– Place the O-ring into the groove of the engine housing.

– Fit preassembled ignition cover and mount the 4 bolts but do not

tighten.

1

2

3

4

6-18D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Adjustment of ignition point (SEM)

NOTE: The ignition point is adjusted after the crankshaft locking bolt
has been mounted.

– Remove the plug at the ignition cover.
– Turn ignition cover so that the mark 

C

on the stator and the mark

A

on the flywheel are aligned.

– Tighten the 4 bolts of the ignition cover.
– Finally, mount the ignition cover plug.

NOTE: The 400 LC4 engine needs more preignition than the other LC4
engines. As all LC4 engines are equipped with the same ignition system,
the flywheel is provided with an additional mark (groove) for the 400
LC4 engine. The ignition adjustment procedure is exactly the same.

– In the 400 LC4 model the marking 

B

(notch) must coincide with the

marking on the stator.

– In the 540 LC4, 620 LC4 and 640 LC4 model the marking 

A

(2 mm

bore) must coincide with the marking on the stator.

Mounting the EPC wiring harness

– Put the wiring harness through the clip at the automatic tensioner

and connect all 3 cable lugs to the contact screws, making sure to
connect each cable to the corresponding screw:

– Connect the black/orange cable to contact screw 

1

.

– Connect the black/green cable to contact screw 

2

.

– Connect the black/blue cable to contact screw 

3

.

A

B

A

C

1

2

3

6-19D

Installing the ignition (Kokusan 4K-3)

– Block the crankshaft with the crankshaft locking bolt.
– Insert the woodruff key into the crankshaft.
– Clean the cone of the flywheel and the crankshaft and mount the

flywheel.

– Mount the spring washer and the collar nut (LH thread).
– Tighten the collar nut with 60 Nm.
– Insert the O-ring 

1

into the groove in the engine housing.

– Mount the pre-assembled ignition cover. Insert the 4 bolts without

tightening them yet.

Adjusting the ignition point (Kokusan 4K-3)

NOTE: The ignition point is adjusted while the crankshaft locking bolt is
still twisted in.

– Remove the plug at the clutch cover.
– Turn the clutch cover until mark 

C

on the pulse generator and mark

A

or 

B

, respectively, on the flywheel coincide.

NOTE: In 400 LC4 engines mark 

B

must coincide with the mark on the

pulse generator.
In 620/660 LC4 engines mark 

A

must coincide with the mark on the

pulse generator.

– Tighten the 4 bolts of the ignition cover.
– Finally, mount the plug.

1

A

B

C

A

B

6-20D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Mounting the oil hoses

– Mount the two oil hoses.
– Tighten banjo bolt 

1

with 10 Nm and banjo bolt 

2

with 15 Nm.

Mounting the clutch release lever

– To mount the clutch release lever 

3

, turn the clutch release shaft

clockwise as far as stop and fit the release lever as illustrated. 

– Tighten clamp bolt

4

.

Mounting the electric starter motor

– Slightly oil the O-ring on the flange of the electric starter motor.
– Mount the electric starter motor and fix it with 2 bolts 

5

.

Mounting the water hoses

– Mount the two water hoses and use the four hose clamps to fasten.

1

2

3

4

5

6-21D

Pouring in engine oil

– Mount oil drain plug 

1

with seal ring and tighten with 30 Nm.

– Mount the magnetic plug 

2

and tighten with 20 Nm.

NOTE: A third plug was installed in the 660 SMC model. Tightening
torque: 20 Nm

– Remove the oil dipstick or the oil filler screw on the clutch cover and

add engine oil (see below for quality and viscosity). Remount the oil
dipstick or the oil filler screw.

! 

CAUTION

!

– O

NLY

USE

HIGH

-

QUALITY

OILS

MEETING

OR

SURPASSING

THE

QUALITY

REQUIREMENTS OF

JASO T903 MA (

FOR SPECIFICATIONS SEE CONTAINERS

). 

– I

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE

ENGINE

.

– Y

OU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE

CRITERIA

.

Oil capacity (up to model 2002) :  1.40 l

Oil capacity (from model 2003 on) :  1.50 l

Mounting the kickstarter and the shift lever

– Put the kickstarter onto the kickstarter shaft, then mount bolt 

3

together with a new Schnorr lock washer 

4

and tighten it. 

– Put the V- seal ring 

5

and the shift lever onto the shifting shaft.

– Mount bolt 

6

together with 2 Nordlock discs 

7

and washer 

8

.

– Adjust the stop rubber for the kickstarter so that it rests against the

kickstarter.

NOTE: As soon as the engine is assembled close all openings providing
access to the engine (intake port, exhaust port, water connections,
bleeding openings ...) with appropriate plugs to prevent small parts
from slipping into the interior of the engine during the further
installation process.

3

4

5

8

7

6

1

1

2

up to model 2001

from model 2002 on

2

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATURE

ELECTRICAL – SUPER COMPETITION  . . . . . . . . . . . . . . . . . . . . . . . . .7-4
CHECKING THE VOLTAGE REGULATOR-RECTIFIER  . . . . . . . . . . . . . . . . . .7-4

CHECKING THE VOLTAGE REGULATOR  . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

CHECKING THE CAPACITOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

ELECTRICAL – LC4 COMPETITION  . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

LEAKAGE INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

REMOVING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

CHARGING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR  . . . . . . . .7-6

CHECKING THE CAPACITOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

CHECKING THE NEUTRAL SWITCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

ELECTRICAL – LC4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

LEAKAGE INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

REMOVING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

CHARGING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR  . . . . . . . .7-9

CHECKING THE CAPACITOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

ELECTRIC STARTER SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-12

CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . .7-12

CHECKING THE DIODE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

CHECKING THE ELECTRIC STARTER MOTOR  . . . . . . . . . . . . . . . . . . . . .7-13

CHECKING THE CLUTCH SWITCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

CHECKING THE EMERGENCY OFF SWITCH  . . . . . . . . . . . . . . . . . . . . . .7-14

TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-14

IGNITION SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

CDI UNIT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

CHECKING THE IGNITION COIL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

TROUBLE SHOOTING IN THE IGNITION SYSTEM  . . . . . . . . . . . . . . . . . .7-16

EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

ELECTRICAL

INDEX

7-1D

7

DISMOUNT / RENEW SOLENOID VALVE FOR EPC  . . . . . . . . . . . . . . . . .7-18

CHECK OF SOLENOID VALVE FOR EPC  . . . . . . . . . . . . . . . . . . . . . . . . .7-18

CONTROLLER OF THE EPC SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

CHECK OF EPC SYSTEM MICROSWITCH  . . . . . . . . . . . . . . . . . . . . . . . .7-19

REPLACING THE EPC SYSTEM MICROSWITCH  . . . . . . . . . . . . . . . . . . . .7-19

CHECK OF IDLE SWITCH / CONTACT SCREWS  . . . . . . . . . . . . . . . . . . .7-19

ELECTRICAL – DUKE-E  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
CHARGING SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

LEAKAGE INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR  . . . . . . .7-21

REMOVING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

CHARGING THE BATTERY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

CHECKING THE CAPACITOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

ELECTRIC STARTER SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-24

CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-24

CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE CLUTCH SWITCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE EMERGENCY OFF SWITCH  . . . . . . . . . . . . . . . . . . . . . .7-25

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

CHECKING THE ELECTRIC STARTER MOTOR  . . . . . . . . . . . . . . . . . . . . .7-26

TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-26

IDLE SWITCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

IGNITION SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

CDI UNIT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE IGNITION COIL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

SPARK PLUG CONNECTOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE SIDE STAND RELAY  . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29

TROUBLE SHOOTING IN THE IGNITION SYSTEM  . . . . . . . . . . . . . . . . . .7-29

ELECTRICAL – SXC ‘99  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
CHECKING THE VOLTAGE REGULATOR  . . . . . . . . . . . . . . . . . . . . . . . . .7-30

CHECKING THE CAPACITOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

INDEX

7-2D