KTM 400-660 LC4 1998-2005 Motorcycle Workshop Repair Service Manual 1999 2000 2001 2002 2003 2004

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This manual covers the LC4 series of motorcycles, including the 400 LC4, 600 LC4, 620 LC4, 625 LC4, 640 LC4, 650 LC4, and 660 LC4 models produced between 1998 and...

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Type: Motorcycle

Vendor:

Sku: 87767

Tags: 1998 1999 2000 2001 2002 2003 2004 2005 Datsun Engines KTM KTM 400-660 LC4 Motorcycle Tune Up Workshop Repair & Servic

Product variants

Description

This manual covers the LC4 series of motorcycles, including the 400 LC4, 600 LC4, 620 LC4, 625 LC4, 640 LC4, 650 LC4, and 660 LC4 models produced between 1998 and 2005. Known for their robust single-cylinder, four-stroke LC4 engine, these motorcycles are engineered for versatility, offering strong performance suitable for both on-road and off-road applications. The heritage in off-road racing informs the LC4's design, emphasizing reliability and capability in demanding conditions. The platform's evolution has consistently focused on enhancing power delivery and durability, making it a staple in the dual-sport and adventure touring segments. This comprehensive workshop repair service manual provides detailed information for owners, DIY enthusiasts, and professional technicians. It covers routine maintenance procedures, engine and transmission repairs, suspension servicing, brake system maintenance, and electrical troubleshooting. The manual includes precise torque specifications, assembly clearances, wear limits, and fluid capacities, ensuring accurate service and repair. With advanced diagnostic capabilities and in-depth rebuild procedures, this manual serves as an invaluable resource for maintaining the performance, reliability, and longevity of your LC4 motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

Model Variants:

400 LC4, 600 LC4, 620 LC4, 625 LC4, 640 LC4, 650 LC4, 660 LC4

Production Years Covered:

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Codes

Engine Code Family:

👋 Introduction

Market Position

Target User:

KTM LC4 motorcycle owners, DIY enthusiasts, independent repair shops, and technicians seeking detailed service information.

Competitive Analysis

Value Proposition:

Offers professional-grade repair and maintenance data at a fraction of the cost of dealership service, enabling cost savings and self-sufficiency in vehicle upkeep.

Key Features

Manual Content Advantage:

Presents information equivalent to the official KTM service manual used by authorized technicians, ensuring accuracy and completeness.

Download Benefit:

Provides immediate access to critical repair information upon purchase, minimizing downtime for necessary maintenance or repairs.

Licensing Terms:

Allows for printing, saving, and transferring the digital file, offering flexibility in usage.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specific to model variants and years)

Page Count

Estimated Page Count:

Likely 300-600 pages (typical for comprehensive workshop manuals)

Manual Type

Manual Format Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Delivery Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine top-end (cylinder head, valves, camshaft), engine bottom-end (crankshaft, connecting rod, piston), lubrication system, cooling system (liquid-cooled variants), fuel system (carburetion, fuel pump for injected models if applicable), ignition system, exhaust system.

Drivetrain Systems:

Clutch operation and service, gearbox (transmission) overhaul, final drive (chain and sprockets maintenance and inspection).

Chassis Systems:

Frame inspection and repair (limited), suspension (forks, shock absorber), steering system, wheels and hubs, brake systems (front and rear discs, calipers, master cylinders, lines), electrical system (wiring diagrams, battery, lighting, starter, charging system), bodywork (fairings, seat, fuel tank).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug inspection and replacement, brake fluid checks, coolant checks, tire pressure checks.

Engine Repair:

Top-end rebuilds (piston, rings, valve seals), decarbonizing, gasket replacement, oil seal replacement, carburetor overhaul, fuel injection system diagnostics (if applicable).

Transmission Repair:

Clutch replacement, gear inspection and replacement, seal replacement.

Suspension Service:

Fork oil changes, seal replacement, shock absorber servicing (where applicable and feasible via manual instructions).

Brake Service:

Brake pad replacement, caliper servicing, master cylinder servicing, brake line bleeding, rotor inspection.

Electrical Troubleshooting:

Wiring diagram interpretation, component testing (e.g., starter, alternator, ignition coil), fuse and relay checks.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues.

Technical Depth

Diagnostic Capability:

Advanced diagnostics with detailed troubleshooting guides and symptom-based problem-solving.

Rebuild Depth:

Comprehensive engine and transmission rebuild procedures, including disassembly, cleaning, inspection, measurement, and reassembly.

Specification Detail:

Inclusion of precise torque specifications for all fasteners, assembly clearances, wear limits for critical components (e.g., piston-to-cylinder bore, valve stem to guide clearance), and fluid capacities.

📊 Manual Specifications

File Format

File Type:

Print Quality

Digital Resolution:

High-resolution (suitable for printing) with clear, legible text and diagrams.

Binding Type

Digital Access:

Instant download with no physical binding.

Paper Type

Digital Compatibility:

Viewable on PC, Mac, tablets, and smartphones.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled (most variants), LC4 denotes 'Liquid Cooling 4-stroke'.

Bore Stroke Variations:

Varies significantly across 400cc to 660cc displacements, requiring specific data per model variant.

Performance

Horsepower Range:

Approximately 30-60 HP depending on displacement and model year.

Torque Characteristics:

Known for strong low-end and mid-range torque, suitable for off-road and dual-sport applications.

Fuel System

Carburetion System:

Primarily Keihin CV carburetors (e.g., Keihin CVK 40, CVK 41) or flatslide carburetors (e.g., Mikuni TM40) depending on the specific model and year. Some later models or variants might have electronic fuel injection (EFI).

Valve Train

Valve Actuation:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) with two valves per cylinder, operated by rocker arms or directly.

Lubrication

Oil System:

Integrated dry-sump lubrication system with a separate oil tank, often located in the frame backbone or under the seat.

🔧 Transmission

Standard

Transmission Type:

Constant mesh, sequential gearbox.

Optional

Gear Ratios:

Specific gear ratios vary by model and are detailed in the manual. Typically 5 or 6-speed.

Features

Clutch Type:

Hydraulically actuated, multi-plate wet clutch.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 1450-1500 mm.

Weights

Dry Weight:

Varies by model, generally in the range of 140-160 kg.

🛡️ Safety Features

Ratings

Crash Test Information:

Not applicable for motorcycles in the same manner as cars; safety focuses on rider protection and vehicle stability features.

Active Features

Braking System:

Hydraulic disc brakes front and rear, typically with Brembo components for high performance and reliable stopping power.

Passive Features

Frame Design:

Chromium-molybdenum steel trellis frame provides rigidity and impact absorption.

💡 Technology Features

Infotainment

Dashboard Display:

Analog tachometer and speedometer, often with basic LCD readouts for odometer, trip meter, and indicator lights. Advanced features like GPS or Bluetooth connectivity are generally absent in this era of models.

Driver Assistance

ABS Availability:

Anti-lock Braking System (ABS) was not a standard or commonly available feature on most LC4 models from this period. Its presence would be model-specific.

Connectivity

Diagnostic Ports:

While not a direct 'infotainment' feature, diagnostic ports (if present for EFI models) would facilitate engine data retrieval using specialized tools, covered within the electrical troubleshooting section.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or annually, whichever comes first. Refer to specific model year for precise intervals.

Air Filter Service:

Check every 3,000 km, clean or replace as needed. More frequent cleaning in dusty conditions.

Spark Plug Replacement:

Inspect every 6,000 km, replace as needed. Specific spark plug types (e.g., NGK CR9EKB) will be detailed in the manual.

Chain Maintenance:

Lubricate and adjust chain tension every 1,000 km or as needed based on slack.

Fluid Specifications

Engine Oil Type:

Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 depending on ambient temperature and manufacturer recommendation. Specific API and JASO specifications will be in the manual.

Engine Oil Capacity:

Approximately 1.5-2.0 liters (including oil tank and filter). Exact capacity varies by model.

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific KTM recommended coolant might be specified.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates (especially with aggressive riding), cam chain tensioner, valve stem seals, fuel tank paint adhesion (on some early models), kickstart mechanism (on models equipped with it).

Performance Tuning Considerations:

Carburetor jetting adjustments may be necessary for different altitudes or exhaust modifications. The manual provides stock specifications for reference.

📚 Vehicle History

Brand Heritage

Ktm Offroad Legacy:

KTM has a strong heritage in off-road racing and performance motorcycles, with the LC4 engine family being a cornerstone of their dual-sport and street-legal enduro models.

Model Evolution

Lc4 Development:

The LC4 platform has evolved significantly over the years, adapting to emissions standards and performance demands, with continuous improvements in reliability and power delivery.

Production

Manufacturing Location:

Primarily Austria, with potential for other assembly locations depending on market.

🏆 Awards & Recognition

Recognitions

Motorcycle Segment Awards:

KTM LC4 models, particularly the 640 Adventure and Enduro variants, received acclaim for their off-road capability, reliability in demanding conditions, and performance in dual-sport and adventure touring segments. Specific awards vary by model year and journalistic reviews.