KTM LC4 400-660LC42003 engine. Manual - part 34

10-69D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

660 SMC

Frame

Central chrome-moly-steel frame

Fork

White Power 4860 MXMA

Wheel travel front/rear

265 / 310 mm  (10,6 / 12,4 in)

Rear suspension

Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing

Front brake

Disc brake with carbon-steel brake disc, and 4 piston brake caliper

Front brake disc

Ø 320 mm (12,8 in)

Rear brake

Disc brake with carbon-steel brake disc 

 220 mm (8.8 in), brake caliper floated

Tyres front

120/70-17

Air press.

2 bar (29 psi)

Tyres rear

160/60-17

Air press.

2,2 bar (31 psi)

Fuel tank capacity

9 liter (2,3 US gallons),  2.5 liter (0,6 US gallons) reserve

Final drive ratio

16:38

Chain

X – Ring  5/8 x 1/4"

Bulps

headlight   . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t)
parking light   . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
indicator lamps   . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light   . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light   . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination   . . . 12V 5W (socket W2,1x9,5 d)

Steering angle

63 °

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat high

910 mm (36,4 in)

Ground clearance

290 mm (11,6 in)

Dead weight without fuel

131 kg (289 lbs)

TECHNICAL SPECIFICATIONS - CHASSIS  660 SMC  2003

660 SMC

WP 1418X738

Compression adjuster

20

Rebound adjuster

15

Spring

4,4 N/mm

Spring preload

28 mm

Air chamber length

110 mm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

660 SMC

WP 0118X730

Compression adjuster

4

Rebound adjuster

8

Spring

70 / 260

Spring preload

22 mm

STANDARD-ADJUSTMENT-SHOCK ABSORBER

10-70D

Hexagon nut at primary gear

M20x1,5

Loctite 243 + 170 Nm

Collar nut flywheel (LC4, ADVENTURE, DUKE)

M16x1,25 links

80° C + 150 Nm

Collar nut flywheel  (SC, SXC)

M12x1 left

60 Nm

Hexagon nut for inner clutch hub

M18x1,5

Loctite 243 + 100 Nm

Collar bolt clutch springs

M6

10 Nm

Kickstarter stop bolt

M12x1,5

50 Nm

Allen head bolt freewheel hub (E-STARTER)

M6x12/M6x12,5

Loctite 648 + 12/16 Nm

Allen head bolts oil pumps

M6

Loctite 243 + 8 Nm

Collar bolts oil pumps (from modell 2003 on)

M6

Loctite 243 + 10 Nm

Hexagon bolt camshaft gear

M10

Loctite 243 + 35 Nm

Allen head bolts cylinder head top section

M6x25/M6x35/M6x65/M6x70 (8.8)

8 Nm

Allen head bolts cylinder head top section

M6x50/M6x55 (12.9)

15 Nm

Bolts cylinder head top section (from model 2003 on)

M6 (8.8)

10 Nm

Bolts cylinder head top section (from model 2003 on)

M7 (12.9)

15 Nm

Cylinder head to cylinder

M8

25 Nm

Cylinder head to cylinder

M6

8 Nm

Cylinder head to cylinder (from model 2003 on)

M6

10 Nm

Cylinder head bolts

M10

50 Nm

Collar nuts at cylinder base

M10

40 Nm

Plug at cylinder head (SC)

M10

20 Nm

Hexagon bolt chain sprocket 8.8

M10

Loctite 243 + 40 Nm

Hexagon bolt chain sprocket 12.9

M10

Loctite 243 + 60 Nm

Nut chain sprocket

M20x1,5

60 Nm

Oil drain plug

M22x1,5

30 Nm

Magnetic plug

M12x1,5

20 Nm

Plug bypass valve

M12x1,5

20 Nm

Banjo bolts oil lines

M8x1

10 Nm

Banjo bolts oil lines

M10x1

15 Nm

Jet screw clutch cover

M8

10 Nm

Plug timing-chain tensioner

M12x1,5

20 Nm

Timing-chain tensioner to cylinder

M6

Loctite 243 + 8 Nm

Timing-chain tensioner to cylinder (from model 2003 on)

M6

10 Nm

Timing-chain guide to cylinder

M12x1,25

Loctite 243 + 8 Nm

Hexagon bolt timing-chain guide

M6

Loctite 243 + 10 Nm

Tension guide

M8

Loctite 243 + 15 Nm

Timing-chain securing guide

M6

8 Nm

Allen head bolt timing-chain securing guide (from model 2003 on)

M6

Loctite 243 + 10 Nm

Counternuts valve adjusting screws

M7x0,75

16 Nm

Crankshaft locking bolt

M8

25 Nm

Spark plug

M12x1,25

20 Nm

Engine mounting bolt

M8

40 Nm

Engine mounting bolt

M10

70 Nm

Retaining plate for main shaft bearing

M6

Loctite 648 + 8 Nm

Retaining plate for main shaft bearing (from model 2003 on)

M6

Loctite 648 + 10 Nm

Shift mechanism support, securing device for bearing

M5

Loctite 243 + 6 Nm

Shift mechanism support

M6

Loctite 243 + 8 Nm

Shift mechanism support (from model 2003 on)

M6

Loctite 243 + 10 Nm

Shift drum locating

M6

Loctite 243 + 8 Nm

Engine housing, clutch cover, ignition cover

M6

10 Nm

Water pump cover

M6

10 Nm

Bolts of impuls generator

M5

Loctite 243 + 6 Nm

Stator (SC)

M6

Loctite 243 + 8 Nm

Stator (E-Start)

M5

Loctite 243 + 6 Nm

Kick starter

M8

25 Nm

Shifting lever

M6

Loctite 243 + 10 Nm

Oil filter cover 

M6

10 Nm

Microfilter cover (SC)

M5

6 Nm

Starter flange, starter cover 

M6

10 Nm

AH bolt for slave cylinder 

M6

10 Nm

Starter

M6

10 Nm

Valve cover 

M6

10 Nm

Exhaust flange 

M6

10 Nm

AH screw for decompression shaft lever 

M6

Loctite 243 + 10 Nm

Retaining shim for ignition (SC) 

M5

Loctite 243 + 6 Nm

Other bolts, engine

M5

6 Nm

M6

10 Nm

TIGHTENING TORQUE - ENGINE

10-71D

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

Collar nut front axle

M16x1,5, M17

40 Nm

Collar nut front axle (400 SXC)

M10

40 Nm

Collar nut front axle

M24x1,5

40 Nm

Collar nut rear axle

M20x1,5

80 Nm

Shock absorber top

M10

45 Nm

Shock absorber bottom

M10

45 Nm

Collar bolts brake disk front

M6

Loctite 243 + 10 Nm

Collar bolts brake disk front

M6

Loctite 243 + 10 Nm

Bolts brake caliper front

M8

Loctite 243 + 25 Nm

Bolts brake caliper front (LC4 Supermoto)

M10

Loctite 243 + 40 Nm

Allen head bolts brake caliper front (DUKE)

M10x1,25

Loctite 243 + 45 Nm

Allen head bolt brake caliper support rear (DUKE)

M10

40 Nm

Allen head bolts brake caliper front (660 SMC)

M10

60 Nm

Bearing bolt linkage arm/frame

M12

60 Nm

Collar nuts rocker arm bolts

M14x1,5

100 Nm

Engine mounting bolt

M10

45 Nm

Ball joint for push rod

M8

Loctite 243 + 25 Nm

Sprocket bolts with nuts

M8

Loctite 243 + 35 Nm

Collar nut swingarm bolt

M14x1,5

100 Nm

Clamping bolts top triple clamp (USD 43)

M8

20 Nm

Clamping bolts top triple clamp (EXTREME)

M8

15 Nm

Clamping bolts top triple clamp (USD 48)

M8

20 Nm

Clamping bolts bottom triple clamp (USD 43)

M8

15 Nm

Clamping bolts bottom triple clamp (EXTREME)

M8

20 Nm

Clamping bolts bottom triple clamp (USD 48)

M8

15 Nm

Clamp bolts for front wheel axle clamp

M8

10 Nm

Collar nut for eccentric chain adjuster (DUKE)

M10

40 Nm

Bolts, handlebar clamp

M8

Loctite 243 + 20 Nm

Allen head bolts handle bar support, damped

M10

Loctite 243 + 20 Nm

(LC4, LC4-SM, SMC, ADVENTURE, DUKE)

Allen head bolts handle bar support, not damped (SC, SC-SM, SXC)

M10

Loctite 243 + 40 Nm

Rim lock

M8

5 Nm

Clamping of steering stemm

M8

20 Nm

Subframe

M8

Loctite 243 + 35 Nm

Spoke nipple

M4

4 Nm

Blocking bolt of adjusting ring for spring preload

M6

8 Nm

Other bolts on chassis

M6

10 Nm

M8

25 Nm

M10

45 Nm

Other collar nuts on chassis

M6

15 Nm

M8

30 Nm

M10

50 Nm

TIGHTENING TORQUE - CHASSIS     

10-72D

ASSEMBLY CLEARANCE, WEAR LIMIT

Crank shaft

axial play  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm

run out of crank stud  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm

Connecting rod bearing

radial play  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm

Cylinder 400

bore  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm

Cylinder 640

bore  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm

Cylinder 660

bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 102.04 mm

Piston forged

assembly clearance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm

Piston cast

assembly clearance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm

Piston rings end gap

compression rings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm

Valves 

seat sealing intake  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
valve guides diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm

Oil pumps

clearance outer rotor - housing  . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor  . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm

Bypaß valve

minimum spring length  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm

Clutch 

Length of springs  . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
Length of the clutch spring 660 SMC . . . . . . . . . . min. 31.5 mm (new 33.5 mm)

Camshaft

diameter of bearing bolt (needle bearing)  . . . . . . . . . . . . . . . . . .min. 19.97 mm

Transmission shafts

axial play  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm

Crankshaft webs – outer dimension

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 mm +/- 0.05 mm

PERIODIC MAINTENANCE SCHEDULE

Repair manual  KTM LC4 

Art.-Nr

.  321030-E            

MODEL 1998
PERIODIC MAINTENANCE SCHEDULE  SX, SXC, SC  . . . . . . . . . . . . . . .11-2

PERIODIC MAINTENANCE SCHEDULE  LC4 COMPETITION, LC4  . . . . .11-3

PERIODIC MAINTENANCE SCHEDULE  ADVENTURE-R  . . . . . . . . . . . .11-4

PERIODIC MAINTENANCE SCHEDULE  DUKE . . . . . . . . . . . . . . . . . . . .11-5

MODEL1999
PERIODIC MAINTENANCE SCHEDULE  SX, SXC, SC  . . . . . . . . . . . . . . .11-6

PERIODIC MAINTENANCE SCHEDULE  LC4 COMPETITION, LC4  . . . . .11-7

PERIODIC MAINTENANCE SCHEDULE  ADVENTURE-R  . . . . . . . . . . . .11-8

PERIODIC MAINTENANCE SCHEDULE  DUKE . . . . . . . . . . . . . . . . . . . .11-9

MODEL 2001
PERIODIC MAINTENANCE SCHEDULE  620 SC . . . . . . . . . . . . . . . . . .11-10

PERIODIC MAINTENANCE SCHEDULE  LC4-E, ADVENTURE  . . . . . . . .11-12

PERIODIC MAINTENANCE SCHEDULE  DUKE . . . . . . . . . . . . . . . . . . .11-14

MODEL 2002
PERIODIC MAINTENANCE SCHEDULE 625 SC  . . . . . . . . . . . . . . . . . .11-16

PERIODIC MAINTENANCE SCHEDULE LC4, ADVENTURE  . . . . . . . . . .11-18

PERIODIC MAINTENANCE SCHEDULE DUKE  . . . . . . . . . . . . . . . . . . .11-20

MODEL 2003
PERIODIC MAINTENANCE SCHEDULE 625 SXC, 660 SMC  . . . . . . . . .11-22

PERIODIC MAINTENANCE SCHEDULE 640 LC4, 640 LC4 ADVENTURE  . . .11-24

PERIODIC MAINTENANCE SCHEDULE DUKE  . . . . . . . . . . . . . . . . . . .11-26

INDEX

11-1D

11

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

11-2D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil







Change oil filter unit







Change microfilter







Check oil lines for leakage and proper instalment





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance



Drain and clean carburator float bowl







Adjust idling



Check breather hoses of engine gase and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreeze



Check cooling system for leaks







Check exhaust system for leakage



Change exhaust muffler packing





Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)



Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check freeplay and easy operation of hand brake lever and foot brake lever







Check adjustment and function of fork





Check fork for leaks



Loosen breather screws at fork legs (overpressure)



Change fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber on forks







Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber





Check O-ring of the shock absorber for wear





Servicing the shock absorber



Grease lubricating nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system and perform a full maintenance job on it



Servicing swingarm pivots



Check tightness of spokes and rim join







Check wheel bearings for clearance





Check chock absorber rubbers on the rear wheel hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check adjustment of head light



Spray ignition lock, short circuit button, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding components







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

1000 km (600 miles)

or 10 hours

after 2500 km  

(1500 miles)

or 25 hours

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING

OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE

NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

SX, SXC, SC

9.97

11-3D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil







Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)

Drain and clean carburetor float chamber







Adjust idling



Check all air supply and ventilation hoses of of the engine and of the carburetor for kinks





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)



Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Loosen bleeder screws at fork legs (overpressure)



Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber of telescopic fork





Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber





Check O-ring of the shock absorber for wear





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR

COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO

BE CARRIED OUT AFTER EACH RIDE OR RACE

400/640 LC4’98

620 LC4 Comp.’98

4. 98

Repair manual  KTM LC4 

Art.-Nr

.  3.206.006 -E

11-4D

Check engine oil level



Change engine oil







Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil







Change oil filter insert







Change fine screen filter (screwed filter) at front pipe (of the frame)







Check oil lines for leakage and proper instalment without kinks





Check valve clearance





Clean spark plug and adjust electrode gap



Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point



Drain and clean carburetor float chamber







Adjust idling



Check breather hoses of engine gase and gas tank for correct position without buckles





Clean air filter and air filter box







Check sprockets, chain guides and chain for wear







Clean and lube chain







Check chain tension







Check cooling liquid level







Check quality of antifreezer



Check cooling system for leaks – visual check







Check exhaust system for leakage



Check exhaust brackets





Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear







Change brake fluid



Check brake pad thickness





Check brake discs



Check condition and correct instalment of brake hoses







Check free play and easy operation of foot brake pedal







Check adjustment and function of telescopic fork





Check telescopic fork for leaks



Loosen bleeder screws at fork legs (overpressure)



Change telescopic fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber of telescopic fork





Check steering head bearing clearance / adjust





Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber





Check O-ring of the shock absorber for wear





Service the shock absorber



Grease nipple of the Pro Lever suspension system



Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it



Service swingarm pivot



Check spoke tension and join







Check wheel bearings for clearance





Check shock absorber rubbers on the rear hub



Check tire condition and air pressure





Check cables for damage and easy working





Lube and adjust cables







Check the electrical system







Check battery holder, battery and connections





Check adjustment of headlight



Spray ignition lock, emergency off switch, and light switch with contact spray





Check all bolts, nuts and hose clamps for proper tightness







Grease or lube all pivot points and sliding points







PERIODIC MAINTENANCE SCHEDULE

befor

e each start

after washing

1st service,   after 

500 km (300 miles)

after 2500 km  

(1500 miles)

after 5000 km  

(3000 miles) or  once a year

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING

OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE

NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE

Adventure-R  3.98