Content .. 24 25 26 27 ..

KTM LC4 400-660LC42003 engine. Manual - part 26

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-5D

TECHNICAL SPECIFICA

TIONS - CHASSIS 400/540 SXC ‘98

400

/540 SXC

Frame

Central chr

ome-moly-steel frame

Fork

Extr

eme

Wheel travel fr

ont/r

ear

285/320 mm (11,2/12,6 in)

Rear suspension

Central shock absorber (WP)

with PRO-LEVER linkage to r

ear

-swingarm with needle bearing

ont brake

Disc brake with carbon-steel brake disc , brake caliper floated

brake disc

= 260 mm (10,2 in)

Rear brake

Disc brake with carbon-steel brake disc

220 mm (8,7 in), brake caliper floated

ront

90/90

- 2

Air pr

essur

e of

oad

1,0 bar (14 psi)

Air pr

ess. r

oad, driver only

1,5 bar (21 psi)

Air pr

ess. r

oad with passenger

–

res r

ear

140/80

- 1

Air pr

essur

e of

oad

1,2 bar (17 psi)

Air pr

ess. r

oad, driver only

2,0 bar (28 psi)

Air pr

ess. r

oad with passenger

–

Fuel tank capacity

9 liter (3 US

gallons)

of that 1,5 liter (0,4 US

gallons) r

eserve

Final drive ratio

400: 14:50 540:15:50

Chain

" O-Ring

Steering angle

62,5°

Wheel base

mm (59,4

0,4 in)

Seat high

940 mm (37 in)

ound clearance

350 mm (13,8 in)

Dead weight without fuel

400: 121 kg (267 lbs) 540: 122 kg (269 lbs)

Collar bolt fr

ont axle

M 1

40 Nm

(30 ft.lb)

Brake caliper fr

ont

M 8

Loctite 243 + 25 Nm

(18 ft.lb)

Collar nut r

ear axle

M 20x1

80 Nm

(59 ft.lb)

Hex. nut swing arm bolt

M 1

100 Nm

(74 ft.lb)

Clamping bolt top triple clamp

M 8

15 Nm

(11 ft.lb)

Clamping bolt bottom triple clamp

M 8

20 Nm

(15 ft.lb)

Clamping bolts fork leg axle passage

M 8

10 Nm

(7,4 ft.lb)

Other bolts chassis

M 6

10 Nm

(7,4 ft.lb)

M 8

25 Nm

(18 ft.lb)

M 10

45 Nm

(33 ft.lb)

TORQUES

WP 09.18.S7.44

Compr

ession adjuster

Rebound adjuster

Spring

4,2 N/mm

Spring pr

eload

7 mm

Air chamber length

155 mm

Capacity per fork leg

ca 800 ccm

Fork oil

SAE 5

ANDARD ADJUSTMENT - FORK

NOTE FOR WHITE POWER FORKS:

The damping units in the left and the right fork leg ar

e of dif

fer

ent design. Make

sur

e not to mix them up in case of r

epair or service works.

WP 01.18.Q7.82

Compr

ession adjuster

Rebound adjuster

Spring

63/260

Spring pr

eload

23 mm

ANDARD-ADJUSTMENT - SHOCK ABSORBER

10-6D

Engine

400 LC4

620 LC4

Design

Liquid-cooled single cylinder 4-str

oke engine with balancer shaft

Displacement

398 cm

609 cm

Bor

e /

Str

oke

89 / 64 mm

101 / 76 mm

Ratio

10,8 : 1

SX: 11,5 : 1 SC: 10,4 : 1

Fuel

unleaded pr

emium gasoline with a least RON

alve timing

4 valves over r

ocker arm and 1 overhead camshaft, camshaft drive thr

ough single chain

Camshaft

249°

(249)

alve timing by 1 mm

IO 22°

BTDC EO 59°

BBDC

14°

BTDC EO 56°

BBDC

valve clear

ence

IC 47°

ABDC EC

10°

TDC

IC 55°

ABDC EC 13°

TDC

alve diameter

Intake: 36 mm Exhaust: 30 mm

alve clear

ence cold

Intake: 0,20 mm Exhaust: 0,20 mm

Intake: 0,15 mm Exhaust: 0,15 mm

Crank shaft bearing

2 cylinder r

oller bearing

Connecting r

od bearing

needle bearing

Top end bearing

onze bushing

Piston

for

ged/cast aluminium alloy

Piston rings

1 compr

ession ring, 1 taper face ring, 1 oil scraper ring

Engine lubrication

for

ced-feed lubrication thr

ough Eaton-Oilpump with oil sump

Engine oil

see bellow #

Engine oil quantity

1,40 liters

Primary ratio

straight gear

ed spur wheels 30 : 81 teeth

Clutch

multi disc clutch in oil bath

Transmission

5-speed claw shifted

Gear ratio

1st

14:35

2nd

15:24

18:21

4th

20:19

5th

22:18

Ignition system

contactless thyristor ignition with electr

onic advanced system type SEM

Ignition timing

adjustment to max. 38 °

BTDC at 6000 rpm

SX: adjustment to max. 38 °

BTDC at 6000 rpm

SC: adjustment to max. 32 °

BTDC at 6000 rpm

Generator

12V 130W

Spark plug

NGK D8EA

Spark plug gap

0,6 mm

Cooling system

liquid cooled, permanent r

otation of cooling liquid thr

ough mechanic driven water pump

Cooling liquid

liter

, 40% antifr

eeze, 60% water

, at least –25 °

(–13 °

Starting equipment

decompr

essor automatic and hand actuated, cold and hot start knob on carbur

etor

TECHNICAL SPECIFICA

TIONS – ENGINE 400/620 SX, SC ‘98

Hexagon nut at primary gear

M20x1,5

Loctite 243 + 170Nm

(125 ft.lb)

Collar nut flywheel

M12x1 LH thr

ead

60 Nm

(44 ft.lb)

Hexagon nut for inner clutch hub

M18x1,5

Loctite 648 + 80 Nm

(59 ft.lb)

Kickstarter stop bolt

M12x1,5

70 Nm

(52 ft.lb)

AH bolts oil pump

Loctite 243 + 8 Nm

(6 ft.lb)

Hexagon bolt camshaft gear

M10

35 Nm

(26 ft.lb)

AH bolt cylinder head top sect.

M6x25

8 Nm

(6 ft.lb)

AH bolt cylinder head top sect.

M6x50/M6x55 (12.9)

20 Nm

(15 ft.lb)

AH bolt cylinder head top sect.

M6x65/M6x70 (8.8)

8 Nm

(6 ft.lb)

Cylinder head bolts

M10

50 Nm

(37 ft.lb)

Collar nuts at cylinder base

M10

40 Nm

(30 ft.lb)

Hexagon bolt chain spr

ocket

M10

Loctite 243 + 40 Nm

(30 ft.lb)

Oil drain plug

M22x1,5

30 Nm

(22 ft.lb)

Magnetic plug

M12x1,5

20 Nm

(15 ft.lb)

Plug bypass valve

M12x1,5

20 Nm

(15 ft.lb)

Banjo bolts oil lines

M8x1

10 Nm

(7 ft.lb)

Banjo bolt oil lines

M10x1

15 Nm

(11 ft.lb)

Jet scr

ew clutch cover

M8x1

10 Nm

(7 ft.lb)

Bolt plug timing-chain tensioner

M12x1,5

20 Nm

(15 ft.lb)

Counternuts valve adjusting scr

ews

M7x0,75

20 Nm

(15 ft.lb)

Spark plug

M12

20 Nm

(15 ft.lb)

TIGHTENING TORQUES - ENGINE

Crank shaft

axial play

.......................................0,03 - 0,12 mm

(0,001-0,005 in)

run out of crank stud

......................max. 0,04 mm

(0,0016 in)

Connecting r

od bearing

radial play

.......................................max. 0,05 mm

(0,0019 in)

axial play

.........................................max. 1,00 mm

(0,04 in)

Piston

assembly clearance 400/620

...........max. 0,12 mm

(0,005 in)

Piston rings end gap

compr

ession rings

............................max. 0,60 mm

(0,023 in)

oil scraper ring

................................max. 0,80 mm

(0,031 in)

alves

seat sealing intake

...........................max. 1,50 mm

0,059 in)

seat sealing exhaust

........................max. 2,00 mm

(0,079 in)

run out of valve heads

....................max. 0,03 mm

(0,001 in)

valve guides diameter

.....................max. 7,05 mm

(0,277 in)

Oil pump

clearance outer r

otor - housing

.......max. 0,20 mm

(0,008 in)

clearance outer r

tor - inner r

otor

...max. 0,20 mm

(0,008 in)

Bypaß valve

minimum spring lenght

...............................25 mm

(1 in)

Clutch discs

wear limit or

ganic

......................................2,5 mm

(0,1 in)

Transmission shafts

axial play

...........................................0,1 - 0,4 mm

(0,004 in)

Clutch

minimum clutchspring lenght

.........

34,5 mm (new 37 mm)(1,36 in - new 1,45 in)

TOLERANCE, ASSEMBL

Y CLEARANCE

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-7D

Engine oil

Use only oil brands, which meet quality r

equir

ements

of API-classes SF

, SG or SH (informations on bottles)

or higher

. Both, mineral and synthetic oils with above

specifications can be used.

CAUTION

OOR

OIL

QUALITY

MINOR

QUANTITY

EFFECT

EARL

ENGINE

WEAR

BASIC CARBURETOR SETTING

Carbur

etor

Carbur

etor setting number

Main jet

Needle jet

Idling jet

Jet needle

Needle position fr

om top

Mixtur

e.adju. scr

ew open

Thr

ottle valve

Starting jet

Performance r

estrictor

PHM 38 SD

300896

150

DR 266

K 51

3 r

1,5 turn

slide stop 22 mm

PHM 38 SD

4894/6

190

DR 270

K 51

2 nd

1,5 turn

–

PHM 40 SD

110996

155

DR 268

K 51

3 r

1,5 turn

slide stop 26 mm

PHM 40 SD

4922

195

DR 272

K 51

2 nd

1,5 turn

–

400 SC

(20 kW)

400 SC

620 SC (20 kW)

620 SX

620 SC

–

0°C

32°F

15W 40

15W 50

15W 60

10W 40

10W 50

10W 60

API: SF

, SG, SH

TEMPERA

TURE

10-8D

TECHNICAL SPECIFICA

TIONS - CHASSIS 400 / 620 SX, SC ‘98

620 SX

400

/620

Frame

Central chr

ome-moly-steel frame

Fork

Extr

eme

Wheel travel fr

ont/r

ear

285/320 mm (11,2/12,6 in)

Rear suspension

Central shock absorber (WP)

with PRO-LEVER linkage to r

ear

-swingarm with needle bearing

ont brake

Disc brake with carbon-steel brake disc , brake caliper floated

brake disc Ø = 260 mm (10,2 in)

Rear brake

Disc brake with carbon-steel brake disc

220 mm (8,7 in), brake caliper floated

ront

80/100-21

90/90

-2

Air pr

essur

e of

oad

1,0 bar (14 psi)

Air pr

ess. r

oad, driver only

–

1,5 bar (21 psi)

res r

ear

110/90-19

140/80

-1

70R

Air pr

essur

e of

oad

1,2 bar (17 psi)

Air pr

ess. r

oad, driver only

–

2,0 bar (28 psi)

Fuel tank capacity

9 liter (3 US

gallons)

of that 1,5 liter (0,4 US

gallons) r

eserve

Final drive ratio

14:48, 1

4:50, 1

5:40, 1

5:45, 15:48 1

5:50, 1

6:40, 1

6:45

Chain

Steering angle

62,5°

Wheel base

mm (59,4

0,4 in)

Seat high

940 mm (37 in)

ound clearance

350 mm (13,8 in)

Dead weight without fuel

115 kg (254 lbs)

400 : 121 kg (267 lbs)

620 : 122 kg (269 lbs)

Max. permissible fr

ont axle load

211 kg (466 lbs)

Max. permissible r

ear axle load

335 kg (737 lbs)

Max. permissible laden weight

350 kg (770 lbs)

Collar bolt fr

ont axle

M 1

40 Nm

(30 ft.lb)

Brake caliper fr

ont

M 8

25 Nm

(19 ft.lb)

+ Loctite 243

Collar nut r

ear axle

M 20x1

80 Nm

(59 ft.lb)

Hex. nut swing arm bolt

M 1

100 Nm

(74 ft.lb)

Clamping bolt top triple clamp

M 8 (Extr

eme)

15 Nm

(11 ft.lb)

M8 (USD)

15 Nm

(11 ft.lb)

Clamping bolt bottom triple clamp

M 8 (Extr

eme)

20 Nm

(15 ft.lb)

M8 (USD)

15 Nm

(11 ft.lb)

Clamping bolts fork leg axle passage

M 7/M8

7/10 Nm

(5/7 ft.lb)

Other bolts chassis

10 Nm

(7 ft.lb)

25 Nm

(19 ft.lb)

M10

45 Nm

(33 ft.lb)

TORQUES

WP 09.18.S7.40

WP 09.18.S7.44

Compr

ession adjuster

Rebound adjuster

Spring

4,4 N/mm

4,2 N/mm

Spring pr

eload

8 mm

7 mm

Air chamber length

140 mm

155 mm

Capacity per fork leg

ca 800 ccm

Fork oil

SAE 5

ANDARD ADJUSTMENT - FORK

NOTE FOR WHITE POWER FORKS:

The damping units in the left and the right fork leg ar

e of dif

fer

ent design. Make

sur

e not to mix them up in case of r

epair or service works.

WP 01.18.Q7.82

WP 01.18.Q7.81

Compr

ession adjuster

Rebound adjuster

Spring

63/260

66/260

Spring pr

eload

23 mm

ANDAR

T-ADJUSTMENT - SHOCK ABSORBER

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-9D

Engine

620 LC4 COMP

Design

Liquid-cooled single cylinder 4-str

oke engine with balancer shaft

Displacement

609 cm

Bor

e /

Str

oke

101 / 76 mm

Ratio

10,4 : 1

Fuel

unleaded pr

emium gasoline with a least RON

alve timing

4 valves over r

ocker arm and 1 overhead camshaft, camshaft drive thr

ough single chain

Camshaft

249°

(249/1)

alve timing by 1 mm

15°

BTDC EO 52°

BBDC

valve clear

ence

IC 54°

ABDC EC 17°

TDC

alve diameter

Intake: 36 mm Exhaust: 30 mm

alve clear

ence cold

Intake: 0,15 mm Exhaust: 0,15 mm

Crank shaft bearing

2 cylinder r

oller bearing

Connecting r

od bearing

needle bearing

Top end bearing

onze bushing

Piston

for

ged/cast aluminium alloy

Piston rings

1 compr

ession ring, 1 taper face ring, 1 oil scraper ring

Engine lubrication

for

ced-feed lubrication thr

ough Eaton-Oilpump with oil sump

Engine oil

see bellow #

Engine oil quantity

2,1 liters including frame

Primary ratio

straight gear

ed spur wheels 30 : 81 teeth

Clutch

multi disc clutch in oil bath

Transmission

5-speed claw shifted

Gear ratio

1st

14:35

2nd

15:24

18:21

4th

20:19

5th

22:18

Ignition system

contactless thyristor ignition with electr

onic advanced system type SEM

Ignition timing

adjustment to max. 32 °

BTDC at 6000 rpm

Generator

12V 130W

Spark plug

NGK DR8EA

Spark plug gap

0,7 mm

Cooling system

liquid cooled, permanent r

otation of cooling liquid thr

ough mechanic driven water pump

Cooling liquid

liter

, 40% antifr

eeze, 60% water

, at least –25 °

(–13 °

Starting equipment

decompr

essor automatic and hand actuated, cold and hot start knob on carbur

etor

TECHNICAL SPECIFICA

TIONS – ENGINE 620 LC4 COMPETITION ‘98

Crank shaft

axial play

.......................................0,03 - 0,12 mm

(0,001-0,005 in)

run out of crank stud

......................max. 0,08 mm

(0,0031 in)

Connecting r

od bearing

radial play

.......................................max. 0,05 mm

(0,0019 in)

axial play

.........................................max. 1,00 mm

(0,04 in)

Piston

assembly clearance

.........................max. 0,12 mm

(0,005 in)

Piston rings end gap

compr

ession rings

............................max. 0,60 mm

(0,023 in)

oil scraper ring

................................max. 0,80 mm

(0,031 in)

alves

seat sealing intake

...........................max. 1,50 mm

0,059 in)

seat sealing exhaust

........................max. 2,00 mm

(0,079 in)

run out of valve heads

....................max. 0,05 mm

(0,002 in)

valve guides diameter

.....................max. 7,05 mm

(0,277 in)

Oil pump

clearance outer r

otor - housing

.......max. 0,20 mm

(0,008 in)

clearance outer r

tor - inner r

otor

...max. 0,20 mm

(0,008 in)

Bypaß valve

minimum spring lenght

...............................25 mm

(1 in)

Clutch discs

wear limit or

ganic

......................................2,5 mm

(0,1 in)

Transmission shafts

axial play

...........................................0,1 - 0,4 mm

(0,004 in)

Clutch

minimum clutchspring lenght

.........

34,5 mm (new 37 mm)(1,36 in - new 1,45 in)

ASSEMBL

Y CLEARANCE, WEAR LIMIT

10-10D

BASIC CARBURETOR SETTING

Carbur

etor

Carbur

etor setting number

Main jet

Needle jet

Idling jet

Jet needle

Needle position fr

om top

Mixtur

e.adju. scr

ew open

Thr

ottle valve

Starting jet

Performance r

estrictor

PHM 40 SD

110996

155

DR 268

K 51

3 r

1,5 turn

slide stop 26 mm

620 LC4 COMP

Hexagon nut at primary gear

M20x1,5

Loctite 243 +170Nm

(125 ft.lb)

Collar nut flywheel

M12x1 LH thr

ead

60 Nm

(44 ft.lb)

Hexagon nut for inner clutch hub

M18x1,5

Loctite 243 + 80 Nm

(59 ft.lb)

Kickstarter stop bolt

M12x1,5

50 Nm

(37 ft.lb)

AH bolts oil pump

Loctite 243 + 8 Nm

(6 ft.lb)

Hexagon bolt camshaft gear

M10

Loctite 243 + 35 Nm

(26 ft.lb)

AH bolt cylinder head top sect.

M6x25

8 Nm

(6 ft.lb)

AH bolt cylinder head top sect.

M6x50/M6x55 (12.9)

20 Nm

(15 ft.lb)

AH bolt cylinder head top sect.

M6x65/M6x70 (8.8)

8 Nm

(6 ft.lb)

Cylinder head bolts

M10

50 Nm

(37 ft.lb)

Collar nuts at cylinder base

M10

40 Nm

(30 ft.lb)

Hexagon bolt chain spr

ocket

M10

Loctite 243 + 40 Nm

(30 ft.lb)

Oil drain plug

M22x1,5

30 Nm

(22 ft.lb)

Magnetic plug

M12x1,5

20 Nm

(15 ft.lb)

Plug bypass valve

M12x1,5

20 Nm

(15 ft.lb)

Banjo bolts oil lines

M8x1

10 Nm

(7 ft.lb)

Banjo bolt oil lines

M10x1

15 Nm

(11 ft.lb)

Jet scr

ew clutch cover

M8x1

10 Nm

(7 ft.lb)

Bolt plug timing-chain tensioner

M12x1,5

20 Nm

(15 ft.lb)

Counternuts valve adjusting scr

ews

M7x0,75

20 Nm

(15 ft.lb)

Spark plug

M 12

20 Nm

(15 ft.Ib)

TIGHTENING TORQUES - ENGINE

Engine oil

Use only oil brands, which meet quality r

equir

ements

of API-classes SF

, SG or SH (informations on bottles)

or higher

. Both, mineral and synthetic oils with above

specifications can be used.

CAUTION

OOR

OIL

QUALITY

MINOR

QUANTITY

EFFECT

EARL

ENGINE

WEAR

–

0°C

32°F

15W 40

15W 50

15W 60

10W 40

10W 50

10W 60

API: SF

, SG, SH

TEMPERA

TURE

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-11D

TECHNICAL SPECIFICATIONS - CHASSIS 620 LC4 COMP. ‘98

620 LC4 COMP.

Frame

Central chrome-moly-steel frame

Fork

WP Extreme

Wheel travel front/rear

280 / 320 mm (11,0 / 12,6 in)

Rear suspension

Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing

Front brake

Disc brake with carbon-steel brake disc , brake caliper floated

brake disc Ø = 300 mm (11,8 in)

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated

Tyres front

90/90-21 T63

Air press. road, driver only

1,5 bar (21 psi)

Air press. road with passenger

2,0 bar (28 psi)

Tyres rear

130/80-18 T63

Air press. road, driver only

2,0 bar (28 psi)

Air press. road with passenger

2,2 bar (31 psi)

Fuel tank capacity

12 liter (3,2 US gallons)

of that 2,5 liter (0,7 US gallons) res

Final drive ratio

16:40

Chain

O-ring

Battery

maintenance-free battery 12V 8Ah

Steering angle

62,5°

Wheel base

1510 ± 10 mm (59,4 ± 0,4 in)

Seat high

955 mm (37,6 in)

Ground clearance

335 mm (13,2 in)

Dead weight without fuel

133 kg (293 lbs)

Max. permissible front axle load

211 kg (466 lbs)

Max. permissible rear axle load

335 kg (737 lbs)

Max. permissible laden weight

350 kg (770 lbs)

Collar bolt front axle

M 10

40 Nm

(30 ft.lb)

Brake caliper front

M 8

25 Nm

(19 ft.lb)

+ Loctite 243

Collar nut rear axle

M 20x1,5

80 Nm

(59 ft.lb)

Hex. nut swing arm bolt

M 14x1,5

100 Nm

(74 ft.lb)

Clamping bolt top triple clamp

M 8

15 Nm

(11 ft.lb)

Clamping bolt bottom triple clamp

M 8

20 Nm

(15 ft.lb)

Clamping bolts fork leg axle passage

10 Nm

(7 ft.lb)

Other bolts chassis

10 Nm

(7 ft.lb)

25 Nm

(19 ft.lb)

M10

45 Nm

(33 ft.lb)

TORQUES

918 S 757

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

10 mm

Air chamber length

160 mm

Capacity per fork leg

ca. 800 ccm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

NOTE FOR WP EXTREME FORKS:
The damping units in the left and the right fork leg
are of different design. Make sure not to mix them
up in case of repair or service works.

118 S 701

Compression adjuster

Rebound adjuster

Spring

66/260

Spring preload

23 mm

STANDARD-ADJUSTMENT - SHOCK ABSORBER

10-12D

TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘98

Engine

400 LC4

640 LC4

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter

Displacement

398 ccm

624.6 ccm

Bore / Stroke

89 / 64 mm

101 / 78 mm

Ratio

10,8 : 1

11 : 1

Fuel

unleaded premium gasoline with a least RON 95

Valve timing

4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain

Camshaft

249° (249/1)

Valve timing by 1 mm

IO 22° BTDC EO 60° BBDC

IO 13° BTDC EO 53° BBDC

valve clearence

IC 47° ABDC EC 4° ATDC

IC 51° ABDC EC 11° ATDC

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearence cold

Intake: 0,20 mm Exhaust: 0,20 mm

0,15 mm Exhaust: 0,15 mm

Crank shaft bearing

2 cylinder roller bearing

Connecting rod bearing

needle bearing

Top end bearing

bronze bushing

Piston

forged/cast aluminium alloy

Piston rings

1 compression ring, 1 taper face ring, 1 oil scraper ring

Engine lubrication

two Eaten-oilpumps

Engine oil

see bellow #

Engine oil quantity

appr. 2,1 liters including frame

Primary ratio

straight geared spur wheels 30 : 81 teeth

Clutch

multi disc clutch in oil bath

Transmission

5-speed claw shifted

Ignition system

contactless DC-CDI ignition with digital advanced system type KOKUSAN

Ignition timing

adjustment to max. 38° BTDC at 6000 rpm

Generator

12V 200W

Spark plug

NGK DR8EA

Spark plug gap

0,7 mm

Cooling system

liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump

Cooling liquid

1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)

Starting equipment

electric starter and kickstarter

Crank shaft

axial play.............................................................................................0,03 - 0,12 mm

(0,001-0,005 in)

run out of crank stud ............................................................................max. 0,08 mm

(0,0031 in)

Connecting rod bearing

radial play .............................................................................................max. 0,05 mm

(0,0019 in)

axial play...............................................................................................max. 1,00 mm

(0,04 in)

Piston

assembly clearance ..............................................................................max. 0,12 mm

(0,005 in)

Piston rings end gap

compression rings .................................................................................max. 0,60 mm

(0,023 in)

oil scraper ring ......................................................................................max. 0,80 mm

(0,031 in)

Valves

seat sealing intake.................................................................................max. 1,50 mm

0,059 in)

seat sealing exhaust ..............................................................................max. 2,00 mm

(0,079 in)

run out of valve heads ..........................................................................max. 0,05 mm

(0,002 in)

valve guides diameter ...........................................................................max. 7,05 mm

(0,277 in)

Oil pump

clearance outer rotor - housing .............................................................max. 0,20 mm

(0,008 in)

clearance outer rotor - inner rotor.........................................................max. 0,20 mm

(0,008 in)

Bypaß valve

minimum spring lenght.....................................................................................25 mm

(1 in)

Clutch discs

wear limit organic ............................................................................................2,5 mm

(0,1 in)

Transmission shafts

axial play.................................................................................................0,1 - 0,4 mm

(0,004 in)

Clutch

minimum clutch spring lenght .................................................34,5 mm (new 37 mm)(1,36 in - new 1,45 in)

ASSEMBLY CLEARANCE, WEAR LIMIT

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