KTM LC4 400-660LC42003 engine. Manual - part 27

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-13D

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

M20x1,5

Loctite 243 + 170Nm (125 ft.lb)

Hexagon nut flywheel

M16x1,25 LH thread

150 Nm (110 ft.lb)

Hexagon nut for inner clutch hub

M18x1,5

80 Nm (59 ft.lb)

Kickstarter stop bolt

M12x1,5

50 Nm (37 ft.lb)

Allen head bolts oil pump

Loctite 243 + 8 Nm (6 ft.lb)

Hexagon bolt camshaft gear

M10

Loctite 243 + 35 Nm (26 ft.lb)

Allen head bolts outer race

M6x12/M6x12,5

Loctite 648 + 18 Nm (13 ft.lb)

Allen head bolt cylinder head top sect.

M6x50/M6x55 (12.9)

20 Nm (15 ft.lb)

Allen head bolt cylinder head top sect.

M6x25/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 sprocket

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)

Crankshaft locating bolt

25 Nm (18 ft.lb)

Hollow bolts oil lines

M8x1

10 Nm (7 ft.lb)

Hollow bolts oil lines

M10x1

15 Nm (11 ft.lb)

Jet screw clutch cover

10 Nm (7 ft.lb)

Bolt plug timing-chain tensioner

M12x1,5

20 Nm (15 ft.lb)

Counternuts valve adjusting screws

M7x0,75

20 Nm (15 ft.lb)

Engine fastening bolt

40 Nm (30 ft.lb)

M10

70 Nm (52 ft.lb)

TIGHTENING TORQUES - ENGINE

for chain

15
16
17

38
40
42
45
48

for chain

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
16:40
16:42
17:38

–

0°C

32°F

15W 40
15W 50
15W 60

10W 40
10W 50
10W 60

API: SF, SG, SH

TEMPERATURE

10-14D

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 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)

–

400 LC4

25 kW

400 LC4

31 kW

BST40-225

080298

142,5

689 X-6

6G5

3 rd

–
–
–

slide stop 17 mm

BST40-225

080298

142,5

689 X-6

6G5

3 rd

–
–
–
–

640 LC4

25 kW

640 LC4

37 kW

BASIC CARBURETOR SETTING

Type

PHM 40 SD

Carb.-setting number

210198

Main jet

155

Needle jet

DR 268

Idling jet

Jet needle

K 51

Needle clip pos. f. top

4. from top

Mixt. adj. screw open

1.5 turns

1,5 turns

Throttle valve

Starting jet

Performance restrictor

slide stop 28mm

–

640 DUKE-E

640 ADV.-R

25 kW

640 DUKE-E

640 ADV.-R

37 kW

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-15D

TECHNICAL SPECIFICATIONS - CHASSIS 400 / 640 LC4 ‘98

400/640 LC4 ‘98

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 IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing

Front brake

Disc brake with carbon-steel brake disc

300 mm (11.8 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc

220 mm (8.7 in), brake caliper floated

Tyres front

90/90 - 21 Enduro 3

Air press. road, driver only

1.5 bar (22 psi)

Air press. road with passenger

2.0 bar (29 psi)

Tyres rear

140/80 - 18 Enduro 3

Air press. road, driver only

2.0 bar (29 psi)

Air press. road with passenger

2.2 bar (31 psi)

Fuel tank capacity

12 liter (3.2 US gallons), 2.5 liter (0,6 US gallons) reserve

Final drive ratio

400 LC4 = 15:45t

640 LC4 = 16:42t

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

355 mm (13.8 in)

Dead weight without fuel

136 kg (300 lbs)

Max. permissible front axle load

211 kg (465 lbs)

Max. permissible rear axle load

335 kg (740 lbs)

Max. permissible laden weight

350 kg (773 lbs)

118S701

Compression adjuster

Rebound adjuster

Spring

66/260

Spring preload

23 mm (0,9 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

918S757

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

10 mm (0,4 in)

Air chamber length

160 mm (6,3 in)

Capacity per fork leg

ca 800 ccm

Fork oil

SAE 5

STANDARD ADJUSTMENT - FORK

Collar bolt front axle

M10

40 Nm

(30 ft.lb)

Brake caliper front

Loctite 243 + 25 Nm

(20 ft.lb)

Collar nut rear axle

M20x1,5

80 Nm

(60 ft.lb)

Hex. nut swing arm bolt

M14x1,5

100 Nm

(74 ft.lb)

Clamping bolt upper fork bridge

25 Nm

(11 ft.lb)

Clamping bolt lower fork bridge

20 Nm

(15 ft.lb)

Clamping bolts fork stubs

10 Nm

(7 ft.lb)

Other bolts chassis

10 Nm

(7 ft.lb)

25 Nm

(20 ft.lb)

M10

45 Nm

(33 ft.lb)

TORQUES

10-16D

TECHNICAL SPECIFICA

TIONS - CHASSIS 640 ADVENTURE R ‘98

640 ADVENTURE R

Frame

Central chr

ome-moly-steel frame

Fork

WP-Extr

eme Ø 50 mm

Wheel travel fr

ont/r

ear

300 / 320 mm (11,8 / 12,6 in)

Rear suspension

Central shock absorber WP

IBS

with PRO-LEVER linkage to r

ear

- swing-arm with needle bearing

ont brake

Disc brake with carbon-steel brake disc

300 mm (11,8 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc

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

res fr

ont

90/90 - 21 54S Endur

o 3

Air pr

ess. r

oad, driver only

1,5 bar (22 psi)

Air pr

ess. r

oad with passenger

2,0 bar (29 psi)

res r

ear

140/80 - 18 70R Endur

o 3

Air pr

ess. r

oad, driver only

2,0 bar (29 psi)

Air pr

ess. r

oad with passenger

2,2 bar (31 psi)

Fuel tank capacity

28 liter (7,4 US gallons), 3,8 liter (1 US gallons) r

eserve

Final drive ratio

16:40 t

Chain

O – Ring

Battery

maintenance-fr

ee battery 12V 8Ah

Steering angle

62,5 °

Wheel base

1510 ±

10 mm (59,4 ±

,4 in)

Seat high

940 mm (37 in)

ound clearance

320 mm (12,6 in)

Dead weight without fuel

154kg (340 lbs)

Max. permissible fr

ont axle load

150 kg (331 lbs)

Max. permissible r

ear axle load

230 kg (507 lbs)

Max. permissible laden weight

380 kg (839 lbs)

01.18.R7.97

Compr

ession adjuster

Rebound adjuster

Spring

70/260

Spring pr

eload

23 mm (0,9 in)

ANDARD-ADJUSTMENT - SHOCK ABSORBER

09.18.S7.55

Compr

ession adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring pr

eload

10 mm (0,4 in)

Air chamber length

155 mm (5,9 in)

Capacity per fork leg

ca 800 ccm

Fork oil

SAE5

ANDARD ADJUSTMENT - FORK

Collar bolt fr

ont axle

M 1

40 Nm

(30 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 upper fork bridge

M 8

15 Nm

(11 ft.lb)

Clamping bolt lower fork bridge

M 8

20 Nm

(15 ft.lb)

Clamping bolts fork stubs

M 8

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

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

10-17D

TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE-E ‘98

Type

640 DUKE last edition

Frame

Central chrome-moly-steel frame

Fork

type

WP - 4054 Roma Top adjuster

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

10 mm (0,4 in)

oil capacity per fork leg

appr. 740 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . type

WP central shock absorber BAVP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

11,3 liter (3 US gallons), out of this 1,5 liter (0,42 US gallons) reserve

Final drive ratio

17 : 38

Chain

o-ring

Lamps

low beam

H1 12V 55W (socket P14,5s)

HS1 12V 35/35W (socket Px43t)

high beam

H1 12V 55W (socket P14,5s)

HS1 12V 35/55W (socket Px43t)

parking light

12V 4W (socket Ba9s)

12V 4W (socket W2.1 9,5D)

speedometer, tachometer light

12V 1,2W (socket W2x4,6d)

12V 1,2W (socket W2x4.6d)

indicator lamp

12V 1,2W (socket W2x4,6d)

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

62,5°

Wheel base

1460 ± 15 mm (57.5 ± 0.6 in)

Seat high

860 mm (33.9 in)

Ground clearance

250 mm (9.9 in)

Front axle

M 17

40 Nm (30 ft.lb)

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 upper fork bridge

M 8

15 Nm (18 ft.lb)

Clamping bolt lower fork bridge

M 8

15 Nm (11 ft.lb)

AH bolts front brake caliper

M10

40 Nm (30 ft.lb)

AH bolt rear brake caliper support

M10

40 Nm (30 ft.lb)

Collar nuts chain tension eccentrics

M10

40 Nm (30 ft.lb)

Clamping bolts fork stubs

M 8

15 Nm (11 ft.lb)

Other bolts chassis

10 Nm (7 ft.lb)

25 Nm (22 ft.lb)

M10

45 Nm (33 ft.lb)

TORQUES

10-18D

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
Pump jet

PHM 38 ND

120198

150 (155)

AB 265
52 (50)

K 11

1,5 turn

50/1

–

33 (38)

PHM 38 ND

120198

150 (155)

AB 265
52 (50)

K 11

1,5 turn

50/1

slide stop 48mm

33 (38)

VHSB 38 QS

081297

185

FN 260 (FN 258)

K 35 (K 32)

1,5 turn

50
40

–
–

VHSB 38 QS

091297

140 (185)

FN 260 (FN 258)

K 35 (K32)

1,5 turn

50
40

slide stop 36mm

–

PHM 40 SD

4922

195

DR 272

K 51

1,5 turn

40
45

–
–

400 SXC

400 SC (20 kW)

540 SXC

540 SXC (20 kW)

620 SX

Engine

400 SXC

540 SXC

620 SX

Design

Liquid-cooled single cylinder 4-stroke engine

Displacement

398 ccm

538,5 ccm

609 ccm

Bore / Stroke

89 / 64 mm

101 / 76 mm

Ratio

10,8 : 1

11,3 : 1

11,5 : 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 42° 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

Crankshaft 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

forced-feed lubrication through 2 Eaten-oilpumps

Engine oil

see bellow #

Engine oil quantity

1,45 liters (0,38 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