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KTM LC4 400-660LC42003 engine. Manual - part 33

10-61D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2002

Frame

Central chrome-moly-steel frame

Fork

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 4357 ROMA 0518716
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 4681

0118W71

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

X-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

880 mm (34,7 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)

10-62D

Engine

625 SXC

Design

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

Displacement

625 ccm

Bore / Stroke

101 / 78 mm

Ratio

11,5 : 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

584-V03/1

Valve diameter

Intake: 36 mm Exhaust: 32 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 Eaton-oilpumps

Engine oil

SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)

Engine oil quantity

1,6 liters (0,42 US gallons)

Primary ratio

straight geared spur wheels 31 : 79 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 DCPR8 E

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

kick - electric starter

TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003

BASIC CARBURATOR SETTING

Type

Keihin FCR-MX 41

Carburator-setting number

4138A

Main jet

165

Jet needle

OBDVT

Idling jet

Main air jet

200

Idling air jet

100

Needle position

5. rd from top

Starting jet

Mixture control screw open

Slide

Performance restrictor

Slide stop

Stop pump membrane

858 / 2,15 mm

Hot start device

3,8 mm

625 SXC

BASIC CARBURETOR SETTING

Type

Mikuni BST40-266

Main jet

152,5

Needle jet

X-6 689

Idling jet

Jet needle

6G5

Needle clip pos. f. top

3. from top

Mixt. adj. screw open

2,25

625 SXC

USA

10-63D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

625 SXC

Frame

Central chrome-moly-steel frame

Fork

White Power 4357 MXMA

Wheel travel front/rear

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

Rear suspension

Central shock absorber (WP BAVP4681) 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)

Rear brake

Disc brake with carbon-steel brake disc

220 mm (8.8 in), brake caliper floated

Tyres front

90/90-21

Air press. offroad

1,0 bar (14 psi)

Air press. road

1,8 bar (26 psi)

Tyres rear

140/80-18

Air press offroad

1,2 bar (17 psi)

Air press. road

2,0 bar (29 psi)

Fuel tank capacity

9 liter (2,3 US gallons), 2.5 liter (0,6 US gallons) reserve

Final drive ratio

16:40 ( USA 15:50) t

Chain

X – Ring 5/8 x 1/4"

Bulps

headlight   . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t)
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)

Battery

maintenance-free battery 12V 8,6 Ah

Steering angle

62,5 °

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat high

980 mm (39,2 in)

Ground clearance

360 mm (14,4 in)

Dead weight without fuel

132 kg (291 lbs)

TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003

625 SXC

WP 0518X729

Compression adjuster

Rebound adjuster

Spring

4,2 N/mm

Spring preload

5 mm

Air chamber length

140 mm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

625 SXC

WP 0118X725

Compression adjuster

Rebound adjuster

Spring

63 / 260

Spring preload

23 mm

STANDARD-ADJUSTMENT-SHOCK ABSORBER

10-64D

Engine

640 LC4

Design

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

Displacement

625 ccm

Bore / Stroke

101 / 78 mm

Ratio

11.5 : 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

584-V03/1

Valve diameter

Intake: 36 mm Exhaust: 32 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/cast aluminium alloy

Piston rings

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

Engine lubrication

two Eaton-oilpumps

Engine oil

SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)

Engine oil quantity

appr. 2,1 liters including frame

Primary ratio

straight geared spur wheels 31 : 79 teeth

Clutch

multi disc clutch in oil bath, hydraulically operated

Transmission

5-speed claw shifted

Gear ratio

1st