Basic Information Identification Make: KTM Model: 400-660 LC4 Series Production Years: 1998-2003 Codes Engine Code Family: LC4 (Liquid Cooled Four-stroke) Introduction Market Position Target Audience: Owners of KTM 400-660 LC4 motorcycles from 1998-2003, ranging from casual riders to experienced mechanics who perform their own maintenance and repairs. Competitive Analysis Value Proposition: Provides dealership-level repair information at a fraction of the cost, enabling owners to maintain their motorcycles effectively and avoid costly dealer labor charges. Offers comprehensive coverage for a wide range of LC4 variants. Key Features Instructional Style: Features detailed step-by-step instructions, critical notes, cautions, and warnings throughout each chapter to guide users through complex procedures. Visual Aids: Includes hundreds of high-quality illustrations, drawings, and photos to aid in component identification and procedural guidance. Enlarged insets highlight critical details. Organization: Numbered table of contents and bold figure numbers facilitate quick and easy navigation to specific information. Manual Details Coverage Areas Covered Models: 400 LC4, 400 LC4-E, 400 / 540 SXC, 400 / 540 SXC (Australia), 400 / 620 SC, 400 / 620 SC (For Competition), 400 / 620 SC (For Australia), 400 / 620 SC (For Germany), 400 / 640 LC4-E (USA), 620 SC, 620 SC SUPERMOTO, 620 LC4 COMPETITION, 625 SXC, 625 SC / 625 SC SUPERMOTO, 640 LC4, 640 LC4 (For USA), 640 LC4-E, SUPERMOTO, 640 ADVENTURE-R, 640 ADVENTURE-R (Dell Orto), 640 ADVENTURE-R (Mikuni), 640 DUKE, 640 DUKE-E, 660 SMC Page Count Total Pages: 380+ Manual Type Type: Service & Repair Manual / Workshop Manual Language Language: English (Assumed, typical for factory manuals of this era) Format Format: PDF (Digital Download) Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for the LC4 engine family, including disassembly, inspection, and reassembly of cylinder head, cylinder block, crankshaft, connecting rod, pistons, valves, camshafts, and timing components. Engine Control System: Diagnosis and repair of electronic fuel injection (EFI) systems and carbureted fuel systems (Dell'Orto, Mikuni), including sensor identification, troubleshooting, and component testing. Cooling System: Detailed procedures for radiator, coolant flow, water pump, thermostat, and fan system maintenance and repair. Includes coolant specifications and bleeding procedures. Ignition System: Troubleshooting and repair of ignition coil, spark plug, CDI unit, and related wiring. Includes ignition timing specifications. Fuel System: Carburetor overhaul, jetting information, fuel pump diagnosis, fuel filter replacement, and fuel tank service. Exhaust System: Inspection and replacement of exhaust components, gaskets, and mounts. Emission control system information may be included. Transmission And Drivetrain: Detailed procedures for transmission disassembly, inspection, and reassembly, including gear selection, clutch components, and final drive chain/sprocket maintenance. Includes gearbox oil specifications. Clutch System: Service and repair of clutch master cylinder, slave cylinder, clutch plates, springs, and linkages. Includes clutch fluid specifications and bleeding procedures. Brake System: Comprehensive coverage of front and rear brake systems, including caliper overhaul, master cylinder service, brake pad replacement, brake fluid specifications and bleeding, and rotor inspection. Suspension System: Front fork service (oil changes, seal replacement, spring inspection), rear shock absorber service, linkage maintenance, and wheel bearing checks. Includes suspension fluid specifications. Wheel And Tire System: Tire pressure recommendations, wheel balancing, spoke tension adjustment, and wheel bearing replacement. Includes recommended tire sizes. Steering System: Handlebar and triple clamp inspection, steering head bearing service and adjustment, and control cable routing and adjustment. Electrical System: Detailed wiring diagrams, troubleshooting guides for starting system, charging system (stator, rectifier/regulator), lighting, instrumentation, and switches. Includes battery specifications. Bodywork And Frame: Fairing removal and installation, fuel tank service, seat removal, frame inspection, and basic body panel repair guidance. Emissions Control Systems: Information on evaporative emission systems (charcoal canister) and potentially exhaust gas recirculation (EGR) if applicable to specific models. Procedures Included Maintenance: Regular scheduled maintenance, including oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake fluid flushes, and coolant checks. Troubleshooting: Diagnostic procedures for common starting, running, electrical, and braking issues. Includes symptom-based troubleshooting charts. Repair Overhaul: Detailed step-by-step instructions for complete engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, and electrical system component replacement. Diagnostics: Includes guidance for diagnosing EFI system faults, electrical circuit issues, and mechanical problems using appropriate tools and techniques. Technical Specifications: Torque specifications for all fasteners, engine timing specifications, valve clearance settings, fluid capacities, and recommended lubricants. Technical Depth Depth: Comprehensive; covers from basic maintenance to full engine and component teardown and rebuild. Designed for both DIY enthusiasts and professional mechanics. Manual Specifications File Format Format: PDF Compatibility: Windows, Mac, Linux Print Quality Printability: Fully printable, allowing users to print specific sections or the entire manual for workshop use. Digital Quality: High-quality scanned PDF, 100% complete and intact, no missing or corrupt pages/sections. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Engine Specifications Primary Engine Type: Single-cylinder, four-stroke, liquid-cooled (LC4 designation) Bore Stroke Variations: Engine displacements typically ranged from 398cc...