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KTM LC4 400-660LC42003 engine. Manual - part 29

10-29D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS 400 LC4 / 640 LC4

(R)

/ SUPERMOTO ‘99

400 LC4 / 640 LC4

640 Supermoto

400 LC4

/ 640 LC4

Frame

Central chrome-moly-steel frame

Fork

WP Extreme

Wheel travel front/rear

280 / 320 mm (11 / 12.6 in)

250 / 290 mm (10 / 11.4 in)

Rear suspension

Central shock absorber (WP) 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

120/70-17

90/90-21

Air press. road, driver only

1.5 bar (22 psi)

2.0 bar (29 psi

1.5 bar (22 psi)

Air press. road with passenger

2.0 bar (29 psi)

2.2 bar (31 psi)

2.0 bar (29 psi)

Tyres rear

140/80-18

160/60-17

140/80-18

Air press. road, driver only

2.0 bar (29 psi)

2.2 bar (31 psi)

2.0 bar (29 psi)

Air press. road with passenger

2.2 bar (31 psi)

2.4 bar (34 psi)

2.2 bar (31 psi)

Fuel tank capacity

12 or 18 liter (3.2 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve

Final drive ratio

400 LC4 - 15:45 640 LC4 - 16:42

17:40

16:42

Chain

O – Ring

Battery

maintenance-free battery 12V 8Ah

Steering angle

62,5 °

63°

62.5°

Wheel base

1510 ± 10 mm (59.4 ± 0.4 in)

Seat high

955 mm (37.6 in)

935 mm (36.8 in)

Ground clearance

375 mm (14.8 in)

355 mm (13.9 in)

Dead weight without fuel

136kg (300 lbs)

137 kg (302 Ibs)

135 kg (298 Ibs)

Max. permissible front axle load

211 kg (465 lbs)

Max. permissible rear axle load

335 kg (740 lbs)

Max. permissible loaden weight

350 kg (773 lbs)

118S701

118Q784

Compression adjuster

Rebound adjuster

Spring

66/260

63/260

Spring preload

23 mm (0,9 in)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

918S757

918S776

Compression adjuster

Rebound adjuster

Spring

4,4 N/mm

Spring preload

10 mm (0,4 in)

15 mm (0,6 in)

Air chamber length

160 mm (6,3 in)

Capacity per fork leg

app. 800 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

(20 ft.lb)

Collar nut rear axle

M 20x1,5

80 Nm

(60 ft.lb)

Hexagon nut swingarm bolt

M 14x1,5

100 Nm

(74 ft.lb)

Clamping bolt upper triple clamp

M 8

15 Nm

(11 ft.lb)

Clamping bolt lower triple clamp

M 8

20 Nm

(15 ft.lb)

Clamping bolts fork stubs

M 8

10 Nm

(7 ft.lb)

Other bolts chassis

M 6

10 Nm

(7 ft.lb)

M 8

25 Nm

(20 ft.lb)

M 10

45 Nm

(33 ft.lb)

TIGHTENING TORQUES - CHASSIS

10-30D

TECHNICAL DATA – ENGINE 640 LC4-E ADVENTURE R ‘99

Engine

640 LC4-E

Design

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

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° (249/1)

Valve timing by 1 mm

IO 13° BTDC EO 53° BBDC

valve clearance

IC 51° ABDC EC 11° ATDC

Valve diameter

Intake: 36 mm Exhaust: 30 mm

Valve clearance cold

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

two Eaten-oilpumps

Engine oil

see below #

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

BASIC CARBURETOR SETTING

Carburetor

BST40-225

Carburetor setting number

080298

090298

Main jet

142,5

Needle jet

689 X-6

Idling jet

Jet needle

6G5

Needle position from top

Mixt. adj. screw open

–

Throttle valve

–

Starting jet

–

Permormance restrictor

slide stop 17 mm

–

640 ADVENTURE

36 kW

640 ADVENTURE

25 kW

10-31D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

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. 0,08 mm (0,0031 in)

Conrod bearing

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

axial play .......................................max. 1,10 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

Engine oil

Use only oil brands, 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

TEMPERATURE

TIGHTENING TORQUES - ENGINE

10-32D

TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘99

640 ADVENTURE R

Frame

Central chrome-moly-steel frame

Fork

WP-Extreme Ø 50 mm

Wheel travel front/rear

300 / 320 mm (11,8 / 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 54S 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 70R 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

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

Final drive ratio

16:40 t

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

940 mm (37 in)

Ground clearance

320 mm (12,6 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 loaden 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

app. 800 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)

Hexagon nut swingarm bolt

M 14x1,5

100 Nm

(74 ft.lb)

Clamping bolt upper triple clamp

M 8

15 Nm

(11 ft.lb)

Clamping bolt lower triple clamp

M 8

20 Nm

(15 ft.lb)

Clamping bolts fork stubs

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)

TORQUES

10-33D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL DATA – ENGINE KTM 640 DUKE ‘99

Type

640 LC4-E

Design

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

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° (249/1)

Valve timing by 1 mm

IO 13° BTDC EO 53° BBDC

valve clearence

IC 53° ABDC EC 11° ATDC

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

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 below #

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

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, kick starter

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

TEMPERATURE

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open

BST40-225

100299

145

689 X-6

6G5

3 rd

2,25 turn

640 DUKE

40 kW

10-34D

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

Loctite 243 + 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)

Crankshaft

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

run out of crank stud ..................max. 0,08 mm (0,0031 in)

Conrod bearing

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

axial play .......................................max. 1,10 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

10-35D

Repair manual KTM LC4

Art.-Nr

. 3.206.006 -E

TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE ‘99

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. 750 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 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

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

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)

Front axle

M 17

40 Nm

(30 ft.lb)

Rear axle

M20x1.5

80 Nm

(59 ft.lb)

Hex. nut swing arm bolt

M14x1.5

100 Nm

(74 ft.lb)

Clamping bolt upper fork bridge

15 Nm

(11 ft.lb)

Clamping bolt lower fork bridge

15 Nm

(11 ft.lb)

Clamping bolts fork stubs

15 Nm

(11 ft.lb)

AH bolts front brake caliper

M10x1,25

Loctite 243 + 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)

Collar nut conrod pro lever system

M12x1,75

60 Nm

(44 ft.lb)

Bolts handlebar clamps

25 Nm

(15 lb.ft)

Bolt adjusting ring spring preload shock absorber

8 Nm

(6 ft.lb9

Other bolts chassis

10 Nm

(7 ft.lb)

25 Nm

(22 ft.lb)

M10

45 Nm

(33 ft.lb)

TIGHTENING TORQUES - CHASSIS

10-36D

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 clearence

IC 42° ABDC EC 4° ATDC

IC 54° ABDC EC 17° 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

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 with oil sump

Engine oil

see below #

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 4K-3

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 SC, Supermoto 2000

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 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

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