Target Audience:
Enduro and dual-sport riders, plus independent mechanics servicing LC4 single-cylinder engines
Key Advantage:
Lightweight, proven LC4 single-cylinder design with strong low-end torque and straightforward maintenance access
Engine Character:
Torquey single-cylinder four-stroke suited to off-road and enduro use
Serviceability:
Simple air/oil-cooled architecture designed for workshop and field servicing
Coverage Areas:
Engine, fuel, cooling, lubrication, electrical, chassis, and general maintenance for the 2000-2003 KTM 400 E
Manual Type:
Factory-style service, repair, and workshop manual
Page Count:
N/A - page count not specified in listing
Delivery Method:
Instant digital download after purchase
Binding:
Digital (PDF document)
Engine:
Complete teardown, inspection, machining specs, and rebuild of the LC4 400cc single
Cylinder Head:
Valve removal, refacing, seat cutting, and head gasket service
Piston and Cylinder:
Piston measurement, ring gap, cylinder honing and clearance specs
Crankshaft:
Connecting rod, bearing, and crank inspection and replacement
Lubrication System:
Oil pump, pressure relief, oil lines, and filter service
Cooling System:
Radiator, hoses, water pump, and coolant specification
Fuel System:
Carburetor disassembly, jetting, float height, and tuning
Ignition and Electrical:
Stator, CDI unit, spark plug, wiring diagrams, and testing procedures
Clutch and Primary Drive:
Clutch pack service, springs, and primary gear inspection
Transmission:
Gearbox disassembly, shift mechanism, and gear inspection
Chassis:
Frame, swingarm, subframe, and fastener torque values
Suspension:
Fork and shock service procedures and settings
Procedures and Technical Depth
Step-by-Step Repair:
Full disassembly and reassembly sequences with illustrations
Torque Specifications:
Factory torque values for all major fasteners
Special Tools:
Required and alternative tool listings for each job
Diagnostics:
Troubleshooting charts for no-start, running, and performance faults
Adjustments:
Valve clearance, carburetor, chain, and control adjustments
Part Numbers:
Exploded views with KTM part references for ordering
Wear Items:
Identification of service-limited components and replacement criteria
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Primary Engine:
KTM LC4 single-cylinder four-stroke, air/oil-cooled
Displacement:
Approximately 400 cc
Engine Options Range:
Single engine configuration for the 400 E; variants across the LC4 family shared the same architecture
Carburetor:
Keihin carburetor (typical for LC4 models of this era)
Fuel Type:
Premium unleaded gasoline
Crash Test Ratings:
N/A - motorcycles of this class are not crash tested
Active Features:
Front and rear disc brakes
Passive Features:
Steel frame structure, engine guards per model trim
Standards Compliance:
Built to applicable DOT/EU motorcycle standards of the era
Oil and Filter:
Engine oil change after every few rides under race use; regular intervals per the manual's maintenance schedule
Valve Clearance:
Check at scheduled intervals covered in the manual
Air Filter:
Clean after dusty rides; replace as needed
Chain:
Lubricate and adjust regularly
Engine Oil:
High-quality motorcycle engine oil per KTM grade specification (details in manual)
Coolant:
Silicate-free motorcycle coolant
Common Wear Items:
Chains, sprockets, brake pads, clutch plates, and piston rings
Watch Points:
Monitor valve clearances, cam chain tension, and clutch wear on high-hour LC4 engines
