🏷️ Basic Information Identification Make: KTM Model: LC4 Series Model Variant: 400, 600, 620, 625, 640, 660 Model Years Covered: 1998, 1999, 2000, 2001, 2002, 2003 Codes Manual Product Code: KTM400-KTM660_LC4_98-03 👋 Introduction Market Position Segment: Dual-sport / Enduro motorcycles Competitive Analysis Competitors: Honda XR series, Yamaha WR/TT-R series, Suzuki DR series, Kawasaki KLR/KLX series Key Features Vehicle Type: Off-road capable, versatile for street and trail use Manual Benefit: Empowers owners and technicians with in-depth knowledge for maintenance and repair, reducing reliance on specialized service centers. Vehicle Purpose: Versatile platform suitable for adventure touring, trail riding, and light off-road competition. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical and electrical repair, maintenance, troubleshooting, and specifications for KTM LC4 motorcycles Troubleshooting Depth: Dedicated section with symptom-based troubleshooting charts and diagnostic procedures. Page Count Total Pages: 387 Manual Type Type: Repair Manual / Service Manual Language Language: English Format Format: Digital (Instant Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/refitting, complete disassembly, servicing of individual components, engine assembly Electrical: Wiring diagrams, electrical system diagnosis, component testing Fuel System: Carburetor systems, fuel delivery, fuel tank servicing Chassis Suspension: Front forks (WP Suspension), rear shock absorber (WP Suspension), swingarm, steering head. Wheels Tires: Wheel hub maintenance, spoke tensioning, tire changing, wheel bearing service. Brakes: Front and rear brake system maintenance, caliper overhaul, brake fluid flush, master cylinder service. Exhaust System: Maintenance and inspection of the exhaust system. Cooling System: Radiator, coolant hoses, water pump, thermostat maintenance and repair. Procedures Included Maintenance: Periodic maintenance schedule, fluid checks and changes, filter replacements Troubleshooting: Diagnostic procedures for common issues, fault finding guides Repair: Detailed step-by-step instructions for component repair and overhaul Carburetor Rebuild: Detailed steps for carburetor disassembly, cleaning, reassembly, and tuning. Engine Timing: Setting ignition timing and valve timing (if applicable for specific models/versions). Electrical Diagnostics: Troubleshooting starting system, ignition system, lighting, and other electrical circuits using wiring diagrams. Engine Rebuild: Comprehensive instructions for complete engine disassembly, inspection, part replacement, and reassembly. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine rebuilds and electrical diagnostics) Specifications Detail: Includes detailed torque specifications, clearances, dimensions, and tolerances for all major components. 📊 Manual Specifications File Format File Type: PDF (assumed, based on 'Instant Download' and no CD-ROM mention) Print Quality Quality: High-resolution, suitable for printing (typical for professional service manuals) Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) Content Organization Section Breakdown: Clear categorization of information into 12 distinct chapters covering service info, general info, engine work, electrical, fuel system, troubleshooting, specs, maintenance schedule, and wiring diagrams. Searchability Text Searchability: Likely searchable text within the PDF document, facilitating quick access to specific topics. ⚙️ Engine Specifications Primary Engine Engine Configuration: Single-cylinder, four-stroke (LC4 denotes Liquid Cooled, 4-stroke) Engine Displacement Range: Approximately 373cc to 659cc (depending on specific model variant: 400, 600, 620, 625, 640, 660) Engine Cooling: Liquid-cooled Bore X Stroke: Varies by specific displacement; detailed figures for each variant are found in the manual. Valve Train: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on the specific LC4 variant, typically with rocker arms. Performance Typical Horsepower: Ranges from approx. 30 HP (400) to 50+ HP (660), specific figures vary by model and year. Typical Torque: Varies with displacement; strong low-to-mid range torque characteristics expected for off-road performance. Fuel System Fuel Delivery: Carburetor (e.g., Mikuni VM, Keihin FCR depending on model and year) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed manual transmission Optional Optional Gearbox: N/A (standard manual transmission) Features Clutch Type: Hydraulically operated, wet multi-disc clutch Final Drive: Chain drive 📐 Dimensions Exterior General Design: Dual-sport motorcycle chassis, typically with upright riding position. Weights Dry Weight Approx: Ranges from approximately 130 kg to 150 kg, depending on specific model and equipment. 🛡️ Safety Features Ratings Safety Features: Standard safety features expected for motorcycles of this era, focusing on braking and handling. No formal crash ratings apply to motorcycles in the same way as cars. Active Features Braking System: Hydraulic disc brakes front and rear. Specific caliper and rotor sizes would be detailed in the manual. Passive Features Frame Construction: Chromoly steel trellis frame, known for rigidity and strength. 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, basic LCD display for odometer, trip meter, and indicator lights. Driver Assistance Rider Aids: None (basic motorcycle technology of the era) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-5,000 km or annually, as specified in the manual. Often includes oil filter replacement. Valve Clearance Check: Commonly every 6,000-10,000 km. Specific intervals detailed in the manual. Fluid Specifications Engine Oil Type: Air-cooled/liquid-cooled motorcycle engine oil, typically SAE 10W-40 or 20W-50, meeting JASO MA standards. Specific viscosity and API/JASO ratings provided in the manual. Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors, mixed...