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KTM LC4 400-660LC42003 engine. Manual - part 28

10-21D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

Engine

400 LC4

620 LC4

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft

Displacement

398 ccm

609 ccm

Bore / Stroke

89 / 64 mm

101 / 76 mm

Ratio

10,8 : 1

10,4 : 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

249/1

Valve timing by 1 mm

IO 22° BTDC EO 60° BBDC

IO 15° BTDC EO 52° BBDC

valve clearance

IC 42° ABDC EC 4° ATDC

IC 54° ABDC EC 17° ATDC

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearance cold

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

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

Crank shaft bearing

2 cylinder roller bearing

Conrod bearing

needle bearing

Top end bearing

bronze bushing

Piston

cast aluminium alloy

Piston rings

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

Engine lubrication

forced-feed lubrication through 2 Eaten-oilpumps

Engine oil

see bellow #

Engine oil quantity

1,6 liters (0,42 US gallons)

Primary ratio

straight geared 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

3rd

18:21

4th

20:19

5th

22:18

Ignition system

contactless thyristor ignition with electronic advanced system type KOKUSAN

Ignition timing

adjustment to max. 40 ° BTDC at 5000 rpm

adjustment to max. 36 ° BTDC at 5000 rpm

Generator

12V 110W

Spark plug

NGK DPR8 EA-9

Spark plug gap

0,90 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

decompressor automatic and hand actuated, cold and hot start knob on carburetor

TECHNICAL SPECIFICATIONS – ENGINE 400/620 Supercompetition ‘99

Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adj. screw open
Throttle valve
Starting jet
Performance restrictor

PHM 38 SD

300896

150

DR 266

K 51

3 rd

1,5 turn

40
45

slide stop 22 mm

PHM 38 SD

4894/6

190

DR 270 (DR 272)

K 51
2 nd

1,5 turn

40
45

–

PHM 40 SD

110996

155

DR 268

K 51

3 rd

1,5 turn

40
45

slide stop 26 mm

PHM 40 SD

4922

195

DR 272

K 51
2 nd

1,5 turn

40
45

–

400 SC (20 kW)

400 SC

620 SC (20 kW)

620 SC

BASIC CARBURETOR SETTING

10-22D

Engine oil

Use only oil brands (Shell Advance Ultra 4), which
meet quality requirements 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 OR MINOR QUANTITY EFFECT EARLY

ENGINE

WEAR

Hexagon nut at primary gear

M 20x1,5

Loctite 243 +170 Nm

(125 ft.lb)

Collar nut flywheel

M 12x1 LH thread

60 Nm

(44 ft.lb)

Hexagon nut for inner clutch hub

M 18x1,5

Loctite 648 + 80 Nm

(59 ft.lb)

Kickstarter stop bolt

M 12x1,5

50 Nm

(37 ft.lb)

AH bolts oil pump

M 6

Loctite 243 + 8 Nm

(6 ft.lb)

Hexagon bolt camshaft gear

M 10

Loctite 243 + 35 Nm

(26 ft.lb)

AH bolt cylinder head top sect.

M 6x25

8 Nm

(6 ft.lb)

AH bolt cylinder head top sect.

M 6x50/M 6x55 (12.9)

20 Nm

(15 ft.lb)

AH bolt cylinder head top sect.

M 6x65/M6x70 (8.8)

8 Nm

(6 ft.lb)

Cylinder head bolts

M 10

50 Nm

(37 ft.lb)

Collar nuts at cylinder base

M 10

40 Nm

(30 ft.lb)

Hexagon bolt chain sprocket

M 10

Loctite 243 + 40 Nm

(30 ft.lb)

Oil drain plug

M 22x1,5

30 Nm

(22 ft.lb)

Magnetic plug

M 12x1,5

20 Nm

(15 ft.lb)

Plug bypass valve

M 12x1,5

20 Nm

(15 ft.lb)

Banjo bolts oil lines

M 8x1

10 Nm

(7 ft.lb)

Banjo bolt oil lines

M 10x1

15 Nm

(11 ft.lb)

Jet screw clutch cover

M 8x1

10 Nm

(7 ft.lb)

Bolt plug timing-chain tensioner

M 12x1,5

20 Nm

(15 ft.lb)

Counternuts valve adjusting screws

M 7x0,75

20 Nm

(15 ft.lb)

Spark plug

M 12x1,25

20 Nm

(15 ft.Ib)

Crankshaft locking bolt

M 8

25 Nm

18 ft.lb)

Engine fastening bolt

M 8

40 Nm

(30 ft.lb)

M 10

70 Nm

(51 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

(0,002 in)

Conrod bearing

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

(0,002 in)

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

(0,04 in)

Piston forged

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

(0,005 in)

Piston cast

assembly clearance ...................................max. 0,05 mm

(0,002 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

(0,080 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 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 length..........................................25 mm

(1 in)

Clutch discs

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

(0,1 in)

Clutch springs

minimum length ...........................34,5 mm (new 37 mm)

(1,36 in - new 1,45 in)

Transmission shafts

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

(0,004 - 0,016 in)

ASSEMBLY CLEARANCE, WEAR LIMIT

–

0°C

32°F

15W 40
15W 50
15W 60

10W 40
10W 50
10W 60

API: SF, SG, SH

TEMPERATURE

10-23D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 Supercompetition ‘99

400 SC

620 SC

Frame

Central chrome-moly-steel frame

Fork

White Power – Up Side Down 43

Wheel travel front/rear

295 / 320 mm (11,6 / 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 Ø 260 mm (10,2 in), brake caliper floated

Rear brake

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

Tyres front

90/90-21 54R

Air pressure offroad

1,0 bar (14 psi)

Air press. road, driver only

1,5 bar (21 psi)

Tyres rear

140/80-18 70R

Air pressure offroad

1,2 bar (17 psi)

Air press. road, driver only

2,0 bar (28 psi)

Fuel tank capacity

9 liter (2,38 US gallons) of that 2,5 liter (0,66 US gallons) reserve

Final drive ratio

16:48 (14:50)

16:40 (15:50)

Chain

5/8 x 1/4 " O-Ring

Steering angle

62,5°

Wheel base

1510 ± 10 mm (59,4 ± 0,4 in)

Seat high

940 mm (37 in)

Ground clearance

375 mm (14,8 in)

Dead weight without fuel

122 kg (269 lbs)

NOTE FOR WHITE POWER 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.

01.18.T7.05

Compression adjuster

Rebound adjuster

Spring

63 / 260

Spring preload

23 mm (0,9 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

05.18.T7.81

Compression adjuster

Rebound adjuster

Spring

4,2 N/mm

Spring preload

6 mm (0,24 in)

Air chamber length

130 mm (5,1 in)

Capacity per fork leg

app. 700 ccm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

Collar bolt front axle

M 10

40 Nm

(30 ft.lb)

Brake caliper front

M 8

Loctite 243 + 25 Nm

(18 ft.lb)

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)

Collar bolts handlebar clamps

M 8

20 Nm

(15 ft.lb)

Collar bolts handlebar support

M 10

40 Nm

(30 ft.lb)

Clamping bolt top triple clamp

M 8

23 Nm

(17 ft.lb)

Clamping bolt bottom triple clamp

M 8

18 Nm

(13 ft.lb)

Clamping bolts fork leg axle passage

M 8

10 Nm

(7 ft.lb)

Other bolts chassis

M 6

10 Nm

(7 ft.lb)

M 8

25 Nm

(18 ft.lb)

M 10

45 Nm

(33 ft.lb)

TIGHTENING TORQUES - CHASSIS

10-24D

Engine

620 LC4 COMPETITION

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft

Displacement

609 cm

Bore / Stroke

101 / 76 mm

Ratio

10,4 : 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

249/1

Valve timing by 1 mm

IO 15° BTDC EO 52° BBDC

valve clearance

IC 54° ABDC EC 17° ATDC

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearance cold

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

Crankshaft bearing

2 cylinder roller bearing

Conrod bearing

needle bearing

Top end bearing

bronze bushing

Piston

cast aluminium alloy

Piston rings

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

Engine lubrication

forced-feed lubrication through 2 Eaten-oilpumps

Engine oil

see bellow #

Engine oil quantity

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

Gear ratio

1st

14:35

2nd 15:24

3rd

18:21

4th

20:19

5th

22:18

Ignition system

contactless thyristor ignition with electronic advanced system type SEM

Ignition timing

adjustment to max. 32 ° BTDC at 6000 rpm

Generator

12V 130W

Spark plug

NGK DPR8 EA-9

Spark plug gap

0,90 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

decompressor automatic and hand actuated, cold and hot start knob on carburetor

TECHNICAL SPECIFICATIONS – ENGINE 620 LC4 COMPETITION ‘99

Hexagon nut at primary gear

M 20x1,5

Loctite 243 +170 Nm (125 ft.lb)

Collar nut flywheel

M 12x1 LH thread

60 Nm

(44 ft.lb)

Hexagon nut for inner clutch hub

M 18x1,5

Loctite 648 + 80 Nm

(59 ft.lb)

Kickstarter stop bolt

M 12x1,5

50 Nm

(37 ft.lb)

AH bolts oil pump

M 6

Loctite 243 + 8 Nm

(6 ft.lb)

Hexagon bolt camshaft gear

M 10

Loctite 243 + 35 Nm

(26 ft.lb)

AH bolt cylinder head top sect.

M 6x25

8 Nm

(6 ft.lb)

AH bolt cylinder head top sect.

M 6x50/M 6x55 (12.9)

20 Nm

(15 ft.lb)

AH bolt cylinder head top sect.

M 6x65/M 6x70 (8.8)

8 Nm

(6 ft.lb)

Cylinder head bolts

M 10

50 Nm

(37 ft.lb)

Collar nuts at cylinder base

M 10

40 Nm

(30 ft.lb)

Hexagon bolt chain sprocket

M 10

Loctite 243 + 40 Nm

(30 ft.lb)

Oil drain plug

M 22x1,5

30 Nm

(22 ft.lb)

Magnetic plug

M 12x1,5

20 Nm

(15 ft.lb)

Plug bypass valve

M 12x1,5

20 Nm

(15 ft.lb)

Banjo bolts oil lines

M 8x1

10 Nm

(7 ft.lb)

Banjo bolt oil lines

M 10x1

15 Nm

(11 ft.lb)

Jet screw clutch cover

M 8x1

10 Nm

(7 ft.lb)

Bolt plug timing-chain tensioner

M 12x1,5

20 Nm

(15 ft.lb)

Counternuts valve adjusting screws

M 7x0,75

20 Nm

(15 ft.lb)

Spark plug

M 12

20 Nm

(15 ft.Ib)

TIGHTENING TORQUES - ENGINE

10-25D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

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)

Conrod 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 ring 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 length..........................................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 clutchspring length...........34,5 mm (new 37 mm)

(1,36 in - new 1,45 in)

ASSEMBLY CLEARANCE, WEAR LIMIT

Engine oil

Use only oil brands,(Shell Advance Ultra 4) which
meet quality requirements 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 OR MINOR QUANTITY EFFECT EARLY

ENGINE

WEAR

–

0°C

32°F

15W 40
15W 50
15W 60

10W 40
10W 50
10W 60

API: SF, SG, SH

TEMPERATUR

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor

PHM 40 SD

110996

155

DR 268

K 51

3 rd

1,5 turn

40
45

slide stop 26 mm

PHM 40 SD

110996

155

DR 268

K 51

3 rd

1,5 turn

40
45

–

620 LC4 COMP.

24 kW

620 LC4 COMP.

37 kW

10-26D

TECHNICAL SPECIFICATIONS - CHASSIS 620 LC4 COMPETITION ‘99

620 LC4 COMPETITION

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 5/8 x 1/4"

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

M 8

10 Nm

(7 ft.lb)

Other bolts chassis

M 6

10 Nm

(7 ft.lb)

M 8

25 Nm

(19 ft.lb)

M 10

45 Nm

(33 ft.lb)

TIGHTENING TORQUES - CHASSIS

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

app. 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

10-27D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘99

Engine

400 LC4-E

640 LC4-E

Design

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

Displacement

398 ccm

625 ccm

Bore / Stroke

89 / 64 mm

101 / 78 mm

Ratio

10,8 : 1

11 : 1

Fuel

unleaded premium gasoline with at least RON 95

Valve timing

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

Camshaft

249/1

Valve timing by 1 mm

IO 22° BTDC EO 60° BBDC

IO 13° BTDC EO 53° BBDC

valve clearance

IC 47° ABDC EC 4° ATDC

IC 51° ABDC EC 11° ATDC

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearance cold

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

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

Crank shaft bearing

2 cylinder roller bearing

Conrod 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

Gear ratio

1st

14:35

2nd

15:24

3rd

18:21

4th

20:19

5th

22:18

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 DPR8 EA-9

Spark plug gap

0,90 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

Engine oil

CAUTION

OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY

ENGINE

WEAR

–

0°C

32°F

15W 40
15W 50
15W 60

10W 40
10W 50
10W 60

API: SF, SG, SH

TEMPERATURE

10-28D

640 LC4

25 kW

400 LC4

31 kW

400 LC4

25 kW

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture adj. screw open
Throttle valve
Starting jet
Performance restrictor

PHM 38 ND

100197

130

AR 264

K 23
2 nd

1,5 turn

50/1

45 (50, 55)

slide stop 51 mm

PHM 38 ND

100197

130

AR 264

K 23
2 nd

1,5 turn

50/1

45 (50, 55)

–

BST40-225

080298

142,5

689 X-6

6G5

3 rd

–
–
–

slide stop 17 mm

BST40-225

090298

142,5

689 X-6

6G5

3 rd

–
–
–
–

640 LC4

37 kW

Hexagon nut at primary gear

M 20x1,5

Loctite 243 + 170 Nm (125 ft.lb)

Hexagon nut flywheel

M 16x1,25 LH thread

150 Nm (110 ft.lb)

Hexagon nut for inner clutch hub

M 18x1,5

80 Nm (59 ft.lb)

Kickstarter stop bolt

M 12x1,5

50 Nm (37 ft.lb)

Allen head bolts oil pump

M 6

Loctite 243 + 8 Nm (6 ft.lb)

Hexagon bolt camshaft gear

M 10

Loctite 243 + 35 Nm (26 ft.lb)

Allen head bolts outer race

M 6x12/M 6x12,5

Loctite 648 + 18 Nm (13 ft.lb)

Allen head bolt cylinder head top sect.

M 6x50/M 6x55 (12.9)

20 Nm (15 ft.lb)

Allen head bolt cylinder head top sect.

M 6x25/M 6x65/M 6x70 (8.8)

8 Nm (6 ft.lb)

Cylinder head bolts

M 10

50 Nm (37 ft.lb)

Collar nuts at cylinder base

M 10

40 Nm (30 ft.lb)

Hexagon bolt chain sprocket

M 10

Loctite 243 + 40 Nm (30 ft.lb)

Oil drain plug

M 22x1,5

30 Nm (22 ft.lb)

Magnetic plug

M 12x1,5

20 Nm (15 ft.lb)

Plug bypass valve

M 12x1,5

20 Nm (15 ft.lb)

Crankshaft locating bolt

M 8

25 Nm (18 ft.lb)

Hollow bolts oil lines

M 8x1

10 Nm (7 ft.lb)

Hollow bolts oil lines

M 10x1

15 Nm (11 ft.lb)

Jet screw clutch cover

M 8

10 Nm (7 ft.lb)

Bolt plug timing-chain tensioner

M 12x1,5

20 Nm (15 ft.lb)

Counternuts valve adjusting screws

M 7x0,75

20 Nm (15 ft.lb)

Engine fastening bolt

M 8

40 Nm (30 ft.lb)

M 10

70 Nm (52 ft.lb)

Crank shaft

axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in)

run out of crank stud ..................max. 0,04 mm (0,0031 in)

Conrod bearing

radial play .....................................max. 0,05 mm (0,002 in)

axial play .......................................max. 1,00 mm (0,043 in)

Cylinder

bore diameter..........................max. 101,04 mm (3,9779 in)

Piston

assembly clearance ......................max. 0,12 mm (0,0047 in)

Piston ring end gap

compression rings........................max. 0,80 mm (0,0315 in)

oil scraper ring...............................max. 1,0 mm (0,0394 in)

Valves

seat sealing intake .......................max. 1,50 mm (0,0591 in)

seat sealing exhaust ....................max. 2,00 mm (0,0788 in)

run out of valve heads ................max. 0,05 mm (0,0019 in)

valve guides diameter..................max. 7,05 mm (0,2778 in)

Oil pump

clearance outer rotor - housing ......max. 0,20 mm (0,0079 in)

clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in)

Bypaß valve

minimum spring length .............................25 mm (0,985 in)

Clutch

clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in)

wear limit organic............................min. 2,5 mm (0,0985 in)

Camshaft

diameter of bearing bolt.............min. 19,97 mm (0,7868 in)
(needle bearing)

Transmission shafts

axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in)

ASSEMBLY CLEARANCE, WEAR LIMIT

TIGHTENING TORQUES - ENGINE

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