🏷️ Basic Information Identification Make: KTM Model: 400-660 LC4 Year: 2003 Codes Engine Code Family: LC4 👋 Introduction Market Position Target Audience: Owners of KTM 400-660 LC4 motorcycles from 2003 seeking to perform their own maintenance and repairs, saving on workshop costs. Also valuable for independent workshops. Competitive Analysis Value Proposition: Provides factory-level technical information and repair procedures, empowering users to maintain their bikes in 100% condition, mirroring the capabilities of professional garages. Key Features Content Detail: Step-by-step explanations, detailed illustrations, technical specifications, and troubleshooting guides ensure comprehensive repair coverage. 📋 Manual Details Coverage Areas General Information: True Frame Body Panels Exhaust: True Maintenance Lubrication: True Cooling System: True Fuel System: True Engine Removal Installation: True Cylinder Head Cylinder Piston: True Clutch Gearshift Linkage: True Crankshaft Transmission: True Front Wheel Suspension Steering: True Rear Wheel Suspension: True Brakes: True Charging System Alternator: True Ignition System: True Electric Starter Starter Clutch: True Lights Meters Switches: True Wiring Diagram: True Trouble Shooting: True Index: True Page Count Estimated Pages: Varies by specific model variant, but expect 300-500 pages for comprehensive coverage. Manual Type Type: Factory Repair Manual / Service Manual Language Language: English (implied by product description and common industry practice for this region/era) Format Format: Likely a digital format (PDF) for modern sales, but original could be printed. 📖 Manual Coverage Systems Covered Powertrain: Engine, clutch, transmission, crankshaft, cooling system, fuel system. Chassis: Frame, body panels, exhaust system, front and rear suspension, steering. Electrical: Charging system, alternator, ignition system, electric starter, starter clutch, lights, meters, switches, wiring diagrams. Braking: Front and rear brake systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustments, lubrication schedules, cooling system checks. Troubleshooting: Diagnostic procedures for common issues and symptoms. Repair And Overhaul: Detailed instructions for engine rebuilds, transmission servicing, suspension component replacement, electrical system diagnostics. Component Installation Removal: Step-by-step guides for removing and reinstalling major components like the engine, wheels, and suspension. Technical Depth Depth: Comprehensive, covering basic to advanced mechanical and electrical procedures. Designed for professional workshops but accessible with basic mechanical knowledge and attention to detail. 📊 Manual Specifications File Format Digital Quality: Assumed high-quality PDF with searchable text and clear, scalable diagrams. If printed, expect professional binding. Print Quality Illustration Clarity: High-resolution illustrations, diagrams, and depth illustrations as stated in the description. Binding Type Original Binding: Likely a spiral-bound or saddle-stitched booklet for ease of use on a workbench if originally printed. Paper Type Original Paper: Durable paper stock suitable for workshop environments if originally printed. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled (LC4 designation) Performance Displacement Range: Covers variants from approximately 400cc up to 660cc. Bore Stroke Variations: Specific bore and stroke dimensions will vary by exact model (e.g., 400, 525, 620, 640, 660 SX, EXC, Duke variants). Fuel System Carburetion: Likely Keihin flat-slide carburetors (e.g., PD or PJ series) or Mikuni depending on specific sub-model and market. Carburetor tuning and jetting information will be included. Fuel Delivery: Gravity feed from fuel tank via fuel tap and fuel lines. Lubrication Oil System: Wet sump lubrication system, with oil filter and oil cooler (on some higher-performance variants). 🔧 Transmission Standard Gearbox Type: Constant mesh, sequential 5-speed or 6-speed transmission, depending on the specific LC4 model. Features Clutch Type: Hydraulically operated, multi-plate wet clutch. Gear Ratios: Specific gear ratios for each gear will be detailed for different engine displacements and models. 📐 Dimensions Weights Dry Weight Range: Varies significantly by model (e.g., SX, EXC, Duke), typically ranging from 130 kg to 155 kg. Oil Capacity: Approximately 1.0 - 1.5 liters, specific to model and engine variant. Manual will specify exact capacity and oil type. 🛡️ Safety Features Ratings Crash Test Info: Motorcycles are not typically subjected to the same standardized crash testing as cars. Focus is on rider safety through design and maintenance. Active Features Braking System: Performance disc brakes (Brembo typically) with specific piston counts and rotor sizes detailed. Passive Features Chassis Integrity: Robust steel frame (e.g., CrMo steel tubing) designed for rigidity and durability. 💡 Technology Features Infotainment Dashboard Features: Analog tachometer, speedometer, odometer, trip meter, indicator lights (neutral, oil pressure, turn signals, high beam). Driver Assistance ABS Availability: ABS was not commonly available or standard on most LC4 models of this era. This manual would not cover ABS if not present. Connectivity Diagnostic Ports: Limited; primarily relies on visual inspection, multimeter testing, and understanding of basic electrical principles as detailed in the manual. No OBD-II equivalent. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000 - 5,000 km or annually, depending on usage and oil quality. Specific interval will be in the manual. Valve Clearance Check: Around 5,000 - 10,000 km. Manual will provide exact intervals and adjustment procedures. Fluid Specifications Engine Oil Type: JASO MA-certified motorcycle engine oil, typically SAE 10W-40 or 15W-50, depending...