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KTM LC4 400-660LC42003 engine. Manual - part 30

10-37D

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. 0.04 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

Engine oil

Use only synthetic oil (Shell Advance Ultra 4), which meet
quality requirements of API-classes SG or SH (informations
on bottles) or higher.

CAUTION

OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE

WEAR

–

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API: SG, SH

TEMPERATURE

10-38D

TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SC, Supermoto 2000

400/620 SC

620 Supermoto

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

Ø 320 mm (12.6 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 Pirelli MT 21

120/70-17 Pirelli MT 60

Air pressure offroad

1.0 bar (14 psi)

–

Air press. road, driver only

1.5 bar (21 psi)

2.0 bar (28 psi)

Tyres rear

140/80-18 Pirelli MT 21

160/60-17 Pirelli MT 60

Air pressure offroad

1.2 bar (17 psi)

–

Air press. road, driver only

2.0 bar (28 psi)

2.2 bar (31 psi)

Fuel tank capacity

9 liter (2.38 US gallons) of that 2.5 liter (0.66 US gallons) reserve

Final drive ratio

400: 16:48 620: 16:40

17:38

Chain

5/8 x 1/4 " O-Ring

Steering angle

62.5°

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat height

940 mm (37 in)

920 mm (36 in)

Ground clearance

375 mm (14.8 in)

355 mm (14 in)

Dead weight without fuel

122 kg (269 lbs)

123 kg (271 lbs)

01.18.T7.05

Compression adjuster

Rebound adjuster

Spring

63 / 260

Spring preload

23 mm (0.9 in)

STANDARD ADJUSTMENT - SHOCK ABSORBER

05.18.U7.82

Compression adjuster

Rebound adjuster

Spring

4.2 N/mm

Spring preload

7 mm (0.28 in)

Air chamber length

120 mm (4.72 in)

Capacity per fork leg

app. 420 ccm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

10-39D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2000

Type

400 LC4-E

640 LC4-E

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

11,0 : 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 13° BTDC EO 53° BBDC

valve clearence

IC 42° 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

Intake: 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

2 Eaton-Oilpumps

Quantity of engine oil

see table

Engine oil

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

DPR8 EA9

Spark plug gap

0.9 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, kick starter

Engine oil

Use only synthetic oils, which meet quality
requirements of API-classes SG or SH (informations
on bottles) or higher.

CAUTION

OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY

ENGINE

WEAR

–

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API: SG, SH

TEMPERATURE

15 t
16 t for chain
17 t

38 t
40 t for chain
42 t

45 t
48 t

30:81

Primary

ratio

Transmission

Available chain
drive sprockets

Available final

drive sprockets

GEAR RATIOS

1st gear

14:35

2nd gear 15:24
3rd gear

18:21

4th gear

20:19

5th gear

22:18

Original final

drive ratio

15:45
16:42
17:38
17:42

10-40D

ASSEMBLY CLEARANCE, WEAR LIMIT

Crank shaft

axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm

run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm

Connecting rod bearing

radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm

Cylinder 400

bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm

Cylinder 640

bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm

Piston forged

assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm

Piston cast

assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm

Piston rings end gap

compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm

Valves

seat sealing intake  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
valve guides diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm

Oil pumps

clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm

Bypaß valve

minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm

Clutch

Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm

Camshaft

diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm

Transmission shafts

axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm

BASIC CARBURETOR SETTING

Type

PHM 38 ND

BST40-225

Carb.-setting number

100197

090298

Main jet

130

142,5

Needle jet

AR 264

689 X-6

Idling jet

Jet needle

K 23

6G5

Needle clip pos. f. top

2. from top

3. from top

Mixt. adj. screw open

1.5 turns

1,5 turns

2,25 turns

Throttle valve

50/1

–

Starting jet

45(50,55)

–

Performance restrictor slide stop 51mm

–

400 LC4-E

25 kW

400 LC4-E

31 kW

400 LC4-E

USA

BASIC CARBURETOR SETTING

Type

BST40-225

Carb.-setting number

080298

090298

100299

Main jet

142,5

145

Needle jet

689 X-6

Idling jet

Jet needle

6G5

Needle clip pos. f. top

3. from top

Mixt. adj. screw open

2,25 turns

Throttle valve

–

Starting jet

–

Performance restrictor slide stop 17mm

–

640 LC4-E, Adventure

25 kW

640 LC4-E, Adventure

36 kW

640 Duke

40 kW

10-41D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2000

400 LC4-E

640 LC4-E

640 LC4-E SUPERMOTO

Frame

Central chrome-moly-steel frame

Fork

White Power – Up Side Down 43

Wheel travel front/rear

270 / 300 mm (10,6 / 11,8 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 Disk front

Ø 300 mm (11,8 in)

Ø 320 mm ( 12,6 in)

Rear brake

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

Tyres front

90/90-21

120/70-17

Air press. road, driver only

1,5 bar (21 psi)

2,0 bar (28 psi)

Air press. road, with passenger

2,0 bar (28 psi)

2,2 bar (31 psi)

Tyres rear

140/80-18

160/60-17

Air press. road, driver only

2,0 bar (28 psi)

2,2 bar (31 psi)

Air press. road, with passenger

2,2 bar (31 psi)

2,4 bar (34 psi)

Fuel tank capacity

11 liter (2,9 US gallons) / 18 liter (4,75 US gallons)

2,5 liter (0,66 US gallons) reserve

Final drive ratio

15:45

16:42

17:42

Chain

5/8 x 1/4 " O-Ring

Lamps

head light . . . . . . . . . . . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illumination . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)

Battery

12V 8Ah

Steering angle

62,5°

Wheel base

1510 ± 10 mm (59,4 ± 0,4 in)

Seat high

935 mm (36,8 in)

915 mm (36 in)

Ground clearance

355 mm (14 in)

335 mm (13,2 in)

Dead weight without fuel

136 kg (300 lbs)

137 kg (302 lbs)

Max. permissable front axe load

211 kg (466 lbs)

Max. permissable rear axe load

335 kg (740 lbs)

Max. permissable laden weigth

350 kg (773 lbs)

WP 0518U790

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

6 mm (0,25 in)

Air chamber length

150 mm (5,9 in)

Capacity per fork leg

ca 410 ccm

Fork oil

SAE5

STANDARD ADJUSTMENT - FORK

WP 0118U707

Compression adjuster

Rebound adjuster

Spring

66 / 260

Spring preload

27 mm (1,1 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

10-42D

TECHNICAL SPECIFICATIONS - CHASSIS LC4 ADVENTURE R 640 2000

LC4 Adventure R 640

Frame

Central chrome-moly-steel frame

Fork

WP Extreme

Wheel travel front/rear

280/320 mm (11/12,6 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 300 mm (11,8 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 Enduro3

Air pressure offroad

1,5 bar (21 psi)

Air press. road, driver only

2,0 bar (29 psi)

Tyres rear

140/80-18 Enduro3

Air press. road, driver only

2,0 bar (29 psi)

Air press. road, with passenger

2,2 bar (32 psi)

Fuel tank capacity

28 liter (7,4 US gallons) of that 3,5 liter (1 US gallons) reserve

Final drive ratio

16 : 42

Chain

5/8 x 1/4 " 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 (37,7 in)

Ground clearance

375 mm (14,8 in)

Dead weight without fuel

154 kg (340 lbs)

Max. permissible front axle load

150 kg (331 lbs)

Max. permissible rear axle load

230 kg (507 lbs)

Max. permissible laden weight

380 kg (839 lbs)

01.18.R7.97

Compression adjuster

Rebound adjuster

Spring

70/260

Spring preload

23 mm (0,9 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

09.18.S7.55

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

10 mm (0,4 in)

Air chamber length

155 mm (5,9 in)

Capacity per fork leg

ca 400 ccm

Fork oil

SAE5

STANDARD ADJUSTMENT - FORK

10-43D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE 2000

Frame

Central chrome-moly-steel frame

Fork

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Multi adjuster 0518U795
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 16, with passenger = 16
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)

Rear suspension

WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing

Shock absorber

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260

Front brake

Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper

Rear brake

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

Tyres

front: 120/70 R 17 58H

rear: 160/60 R 17 69H

Air pressure rider only

2.0 bar (29 psi)

2.2 bar (32 psi)

Air pressure with passenger

2.2 bar (32 psi)

2.4 bar (35 psi)

Fuel tank capacity

11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve

Final drive ratio

17 : 38

Chain

O-ring 5/8 x 1/4"

Lamps

low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)

Battery

maintenance-free battery 12V 8Ah

Steering angle

64,2°

Wheel base

1460 ± 15 mm (57.5 ± 0.6 in)

Seat high

860 mm (33.9 in)

Ground clearance

250 mm (9.9 in)

Dead weight without fuel

145 kg (3 lbs)

Max. permissible front axle load

150 kg (2 lbs)

Max. permissible rear axle load

200 kg (4 lbs)

Max. permissible laden weight

350 kg (773 lbs)

10-44D

TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE 2000 USA, AUS

Frame

Central chrome-moly-steel frame

Fork

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (45 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)

Rear suspension

WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing

Shock absorber

Front brake

Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper

Rear brake

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

Tyres

front: 120/70 R 17 58H

rear: 160/60 R 17 69H

Air pressure rider only

2.0 bar (29 psi)

2.2 bar (32 psi)

Air pressure with passenger

2.2 bar (32 psi)

2.4 bar (35 psi)

Fuel tank capacity

12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve

Final drive ratio

17 : 38

Chain

O-ring 5/8 x 1/4"

Lamps

Battery

maintenance-free battery 12V 8Ah

Steering angle

64,2°

Wheel base

1460 ± 15 mm (57.5 ± 0.6 in)

Seat high

860 mm (33.9 in)

Ground clearance

250 mm (9.9 in)

Dead weight without fuel

145 kg (3 lbs)

Max. permissible front axle load

150 kg (2 lbs)

Max. permissible rear axle load

200 kg (4 lbs)

Max. permissible laden weight

350 kg (773 lbs)

Content .. 28 29 30 31 ..