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KTM LC4 400-660LC42003 engine. Manual - part 32

10-53D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2001

640 LC4 Adventure

Frame

Central chrome-moly-steel frame

Fork

WP USD

Wheel travel front/rear

275/300 mm (10,5/12 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 320 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

1,8 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

355 mm (14,2 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.V709

Compression adjuster

Rebound adjuster

Spring

66/260

Spring preload

27 mm (0,9 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

14.18.V704

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

4 mm

Air chamber length

120 mm

Capacity per fork leg

ca 420 ccm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

10-54D

TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE 2001

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)

10-55D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE 2001 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)

10-56D

Engine

625 LC4

Design

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

Displacement

625 ccm

Bore / Stroke

101 / 78 mm

Ratio

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 diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearence cold

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 aluminium alloy

Piston rings

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

Engine lubrication

two oilpumps

Engine oil

10W-40 (Shell Advance Ultra 4)

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 DC-CDI ignition with digital advanced system type KOKUSAN 4K-3C

Ignition timing

adjustment to max. 38 ° BTDC at 6000 rpm

Generator

12V 150 W

Spark plug

NGK DPR8 EA-9

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

Kickstarter, cold start knob on carburetor

TECHNICAL SPECIFICATIONS – ENGINE 625 SC, 625 SC SUPERMOTO 2002

625 SC,

625 SC SUPERMOTO

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet

Main air jet
Idling air jet
Needle position from top
Throttle valve
Starting jet
Performance restrictor

Stop pump membrane

Keihin FCR41

140501

180

OBDVT

200
100

5th

15
85

Slide stop 23mm

3,2mm

10-57D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

625 SC

625 SC SUPERMOTO

Frame

Central chrome-moly-steel frame

Fork

White Power 4357 MXMA

Wheel travel front/rear

295 / 320 mm (11,8 / 12,8 in)

270 / 320 (10,8 / 12.8 in)

Rear suspension

Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing

Front brake

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

Front brake disc

Ø 260 mm (10,4 in)

Ø 320 mm (12.8 in)

Rear brake

Disc brake with carbon-steel brake disc

220 mm (8.8 in), brake caliper floated

Tyres front

90/90-21

120/70-17

Air press. offroad

1,0 bar (14 psi)

Air press. road

1,8 bar (26 psi)

2,0 bar (29 psi)

Tyres rear

140/80-18

160/60-17

Air press offroad

1,2 bar (17 psi)

Air press. road

2,0 bar (29 psi)

2,2 bar (32 psi)

Fuel tank capacity

9 liter (2,3 US gallons), 1.5 liter (0,4 US gallons) reserve

Final drive ratio

16:40 (15:50) t

17:38t

Chain

X – Ring 5/8 x 1/4"

Bulps

headlight   . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light   . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
indicator lamps   . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light   . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light   . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination   . . . 12V 5W (socket W2,1x9,5 d)

Steering angle

62,5 °

63°

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat high

950 mm (38 in)

920 mm (36.8 in)

Ground clearance

340 mm (13,6 in)

300 mm (12 in)

Dead weight without fuel

122 kg (269 lbs)

123 kg (271 Ibs)

TECHNICAL SPECIFICATIONS - CHASSIS 625 SC, 625 SC SUPERMOTO 2002

625 SC

625 SC SUPERMOTO

WP 0518W712

WP 0518W722

Compression adjuster

Rebound adjuster

Spring

4,2 N/mm

5,0 N/mm

Spring preload

5 mm

9 mm

Air chamber length

140 mm

130 mm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

625 SC

625 SC SUPERMOTO

WP 0118W714

WP 0118W721

Compression adjuster

Rebound adjuster

Spring

63 / 260

75 / 260

Spring preload

23 mm

15 mm

STANDARD-ADJUSTMENT - SHOCK ABSORBER

10-58D

TECHNICAL DATA – ENGINE 640 LC4 2002

Engine

640 LC4

Design

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

Displacement

624,6 ccm

Bore / Stroke

101 / 78 mm

Ratio

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

249/1

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearence cold

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 aluminium alloy

Piston rings

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

Engine lubrication

two oilpumps

Engine oil

10W-40 (Shell Advance Ultra 4)

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