8-11E

Art.-Nr. 3.206.014 -E
Repair manual KTM LC4
CARBURETOR – DELL’ORTO PHM 40 SD

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 8-12E
Disassembling the carburetor (Dell’Orto PHM 40 SD)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.

– Remove the two screws and pull the carburetor cover out of the
carburetor together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo screw bk and take the starting piston out of the carburetor.
10

– Remove the plug 1 together with the seal ring and take off the float
chamber.
1

– Remove the main jet 2, the main jet holder 3 and the baffle 4.
2 4 – Twist out the starting jet 5.

– Remove the idling jet 6 together with the idle mixture pipe below.
– Twist out the needle jet 7.
6

– Pull out the pin 8 and remove the float.

– Remove the entire needle valve 9 together with the gasket behind.

8
9

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 8-13E
– Twist the mixture adjusting screw 1 clockwise all the way in,
counting and writing down the number of twists. Twist out the
3 mixture regulating screw and remove it together with the spring, the
washer and the O-ring.

– Twist the adjusting screw 2 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
and remove it together with the spring, the O-ring and the washer.

1
2

– Remove screw 3, and take off the hose connection together with
the fuel filter 4.

3
– Clean all jets and other components and blow them through with
compressed air.
– Clean the carburetor housing and use compressed air to blow
through all ducts within the carburetor.

– Check all gaskets for damage and exchange them, if necessary.

4

Assembling the carburetor (Dell’Orto PHM 40 SD)

– Put the spring, the washer and the O-ring onto the mixture adjusting
screw 1 and twist the mixture adjusting screw all the way in.
Art.-Nr. 3.206.014 -E

– Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.

– Put the spring, the washer and the O-ring onto the adjusting screw
2 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.

– Insert the fuel filter into the carburetor. Properly position the hose
connection and mount screw 3 together with the seal ring.
3
Repair manual KTM LC4

1
2

– Insert the seal ring into the carburetor bore and mount the needle
valve 5.

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 8-14E
– Position the float and mount the pin 1. When mounting the float
make sure that the needle valve properly engages with the float.
Check by moving the float upwards: the needle valve must move
with the float.

– Mount the idling mixture pipe and the idling jet 2.

– Mount the needle jet 3.
2

– Position the baffle 4 and fasten it with the main jet holder 5.
6 – Mount and tighten the main jet 6.
4 – Mount and tighten the starting jet 7.

Check the O-ring 8 in the float chamber for proper fit.

– Position the float chamber and fasten it with the plug 9. Do not
forget the seal ring.
9

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 8-15E

Art.-Nr. 3.206.014 -E
Repair manual KTM LC4
CARBURETOR – DELL’ORTO PHM 38 ND

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 8-16E
Disassembling the carburetor (Dell’Orto PHM 38 ND)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.

– Remove the two screws and pull the carburetor cover out of the
carburetor together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo screw and take the starting piston out of the carburetor.

– Remove the plug 1 together with the seal ring and take off the float
1 chamber.

– Remove the main jet 2, the main jet holder 3 and the baffle 4.
2 – Twist out the starting jet 6.
– Twist out the return valve 5.
3
4
5

– Remove the idling jet 8 together with the idle mixture pipe below.
– Twist out the needle jet 7.
8

– Pull out the pin 9 and remove the float.

– Remove the entire needle valve bk together with the gasket behind.
9

10

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 8-17E
– Twist the mixture adjusting screw 1 clockwise all the way in,
counting and writing down the number of twists. Twist out the
mixture regulating screw and remove it together with the spring, the
washer and the O-ring.

– Twist the adjusting screw 2 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
and remove it together with the spring, the O-ring and the washer.

1
2

– Remove screw 3, and take off the hose connection together with
the fuel filter.

– Twist out the jet holder 4 together with the accelerating jet 5.
Art.-Nr. 3.206.014 -E

4
5

– Remove the 3 screws 6 and take off the entire pump housing 7
together with the gasket.
7 ! CAUTION !
6 – DO NOT DAMAGE THE MEMBRANE WHEN REMOVING THE PUMP HOUSING.
REMOVE THE MEMBRANE BEFORE CLEANING THE PUMP HOUSING.
– ADJUSTMENT SCREW 8 IS FACTORY CALIBRATED AND MUST NOT BE TURNED.

– Clean all jets and other components and blow them through with
compressed air.
– Clean the carburetor housing and use compressed air to blow
Repair manual KTM LC4

through all ducts within the carburetor.

8 – Check all gaskets for damage and exchange them, if necessary.

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 8-18E
Assembling the carburetor (Dell’Orto PHM 38 ND)
– Position the pump housing 1 together with the gasket and fasten
1 them with the 3 screws. Make sure that the membrane is properly
positioned in the pump housing.

– Put the seal ring onto the jet holder 3 and mount the jet holder
together with the accelerating jet 4. The flat section of the
accelerating jet must face backwards.

3 4

– Insert the fuel filter into the carburetor. Position the hose connection
and mount screw 5 together with the seal ring.

– Put the spring, the washer and the O-ring onto the mixture adjusting
screw 6 and twist the mixture adjusting screw all the way in.
7 – Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.

– Put the spring, the washer and the O-ring onto the adjusting screw
7 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.

– Insert the seal ring into the carburetor bore and mount the needle
valve 8.

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 8-19E
– Position the float and mount the pin 1. When mounting the float
make sure that the needle 2 valve properly engages with the float.
1 Check by moving the float upwards: the needle valve must move
with the float.

– Mount the idling mixture pipe and the idling jet 4.

4 – Mount the needle jet 3.

– Position the baffle 5 and fasten it with the main jet holder 6.
7 – Mount and tighten the main jet 7.
– Mount and tighten the starting jet 8.
– Mount the return valve 9.
Art.-Nr. 3.206.014 -E

6
5

8
9

Check the O-ring bk in the float chamber for proper fit.

10
Repair manual KTM LC4

– Position the float chamber and fasten it with the plug bl. Do not
forget the seal ring.

11

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 8-20E

CARBURETOR – DELL’ORTO VHSB 38 QS

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 8-21E
Disassembling the carburetor (Dell’Orto VHSB 38 QS)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.

– Open the cap and pull the carburetor cover out of the carburetor
together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo the screw and pull the entire cold-starting device out of the
carburetor.

– Remove the three screws 1 and take off the float chamber together
with the gasket.
– Take the two floats out of the carburetor.
– Take the perforated bushing off the baffle.

– Remove the main jet 2 and the baffle 3.

2 – Twist out the starting jet 4 and the idling jet 5.
Art.-Nr. 3.206.014 -E

3
5

– Pull out pin 6 and remove the float arm 7.

7
Repair manual KTM LC4

– Remove the entire needle valve 8 together with the seal ring
behind.

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 8-22E
– Twist out the needle jet 1.
1

– Twist the mixture adjusting screw 2 clockwise all the way in,
counting and writing down the number of twists. Twist out the
mixture regulating screw and remove it together with the spring, the
3 washer and the O-ring.

– Twist the adjusting screw 3 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
2 and remove it together with the spring.

– Remove plug 5 together with the seal ring and take off the fuel
filter 4.

– Clean all jets and other components and blow them through with
compressed air.
4 – Clean the carburetor housing and use compressed air to blow
through all ducts within the carburetor.

– Check all gaskets for damage and exchange them, if necessary.

Assembling the carburetor (VHSB 38 QS)

– Put the spring, the washer and the O-ring onto the mixture adjusting
3 screw 2 and twist the mixture adjusting screw all the way in.
– Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.
2 – Put the spring, the washer and the O-ring onto the adjusting screw
3 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.

– Insert the fuel filter 4 into the plug 5 and mount the plug together
with the seal ring.

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 8-23E
– Mount the needle jet 1.
– Insert the seal ring into the carburetor bore and mount the needle
1 valve 2.

– Position the float arm 3 and mount pin 4.

– Mount the idling jet 5 and the starting jet 6.

8 – Position the baffle 7 and fasten it with the main jet 8.
Art.-Nr. 3.206.014 -E

6 5

– Put the perforated bushing 9 onto the baffle and mount the gasket.
9
Repair manual KTM LC4

– Insert the two floats bk into the float chamber and mount the float
chamber.
10

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 8-24E

main jet
jet needle

jet needle

idling jet
throttle valve

mixture regulating screw

idle adjusting screw

Idling range – A
Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting
screw 2. Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed
is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.

The throttle stop screw is used to adjust the basic position of the throttle. The mixture control screw is used to control the idle
mixture which arrives at the engine via the idle system. Turning it clockwise will reduce the amount of gasoline (lean mixture),
turning it counterclockwise will increase the amount of gasoline (rich mixture).

TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:

1 Turn in mixture control screw up to the stop, and turn it back out by 1.5 turns
2 Warm up the engine
3 Use throttle stop screw to adjust normal idling speed (1400-1500 r.p.m.)
4 Turn mixture control screw slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture
control screw slowly counterclockwise until the idling speed will decrease again. Adjust the point of the highest idling speed
between these two positions. (The highly competitive user will make his adjustment 1/4 turn leaner because his engine will
heat up more in competitive use).

NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling
nozzle may be the cause. In case:
a) the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller
idling jet has to be installed;
b) the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected;
Naturally, in cases of jet changes, you have to start your adjusting work from the beginning.
5 Now, use the slide stop screw to adjust the desired idling speed
6 In cases of greater changes in outside temperature and extremely different altitudes, the idling speed should be readjusted.

Opening up – B
Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good
idling-speed and part-throttle setting, the engine sputters when the throttle is fully opened and develops its full power not
smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float
needle is leaking.

Part-throttle range – C
Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-
throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range.

Full throttle range – D

Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the
new spark plug is found to have a very bright or white coating after a short distance of riding flat out, a larger main jet is
required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause
carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).

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 8-25E

Mixture too rich:

Too much fuel in proportion to air

Mixture too lean:

Not enough fuel in proportion to air
2 1

Check float level (Dell’Orto PHM 38ND / 40SD)

Stand the carburettor diagonally at about 60° so that the spring in the
float needle valve is not pressed together. In this position, the edge of
the float should be parallel with the float bowl sealing surface (see
illustration).

60°

Checking axial play of float (Dell’Orto PHM 38ND / 40SD)

For proper functioning of the float, there must be an axial play of 0.8
mm (0,03 in). If necessary, slightly abrade and deburr lateral float guide.
Art.-Nr. 3.206.014 -E

0,8 mm

Adjust hot start device (Dell’Orto PHM 40SD)

3 If the hot start button was removed when cleaning the carburetor,
readjust the hot start device.
Install carburetor and adjust idling as discribed above. Then unlock nut
1, press in hot start device 2 and adjust engine rev with adjusting
screw 3 to 2000-2500 rpm. Tighten locking nut.
Repair manual KTM LC4

1
2

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 8-26E
Adjusting the throttle cable
There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable.
3-5 mm To check this, move back the protective cover 1 on the throttle grip.
You must be able to lift the outer covering of the cable 3-5 mm from
the adjusting screw 2, until resistance is felt.
To adjust, loosen the counter nut 3 and turn the adjusting screw
accordingly. Finally tighten counter nut and slide the protective cover
back on.

3 2 1

Adjusting the choke cable

At the choke cable, there must always exist a play of approx. 2 mm (0.1
in). To check this, push choke lever fully forward and pull protective
cover 4 from the adjuster piece 5. Now, it must be possible to lift the
outer covering of the cable by approx. 2 mm from the adjuster piece
until feeling a resistance. If necessary, loosen counter nut and readjust
4 play by turning the adjuster piece. Tighten counter nut, and slide on
5 2 mm protective cover.

Adjusting the choke cable

The choke cable must have a play of approximately 2 mm at all times.
To check the play turn the knob 6 into the initial position. Now it
should be possible to lift the exterior case of the choke cable
approximately 2 mm from the supporting surface of the choke knob
before the upward movement is blocked by resistance.
2 mm

To adjust, remove the seat and the gastank, push the protective cover
upwards, loosen the counter nut and turn the adjustment screw 7
accordingly. Turn the adjustment screw clockwise for more play or
anticlockwise for less play.
Tighten the counter nut, replace the protective cover and mount the
gas-tank and the seat.
7

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