10-50D

TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2001

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 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 NGK 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

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
 10-51D
GEAR RATIOS
Primary Original final Available chain Available final
Transmission
ratio drive ratio drive sprockets drive sprockets
1st gear 14:35 38 t
2nd gear 15:24 15:45 15 t 40 t for chain
30:81 3rd gear 18:21 16:42 16 t for chain 42 t 5/8 x 1/4"
4th gear 20:19 17:38 17 t 5/8 x 1/4" 45 t
5th gear 22:18 17:42 48 t

Engine oil
Use only oil brands, which meet quality requirements (Shell Advance
API: SG, SH Ultra 4) of API-classes SG or SH (informations on bottles) or higher.
! CAUTION !
TEMPERATURE
 
POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.
– 0°C
32°F +
10W 40 15W 40
10W 50 15W 50
Art.-Nr. 3.206.006 -E

BASIC CARBURETOR SETTING

400 LC4-E 400 LC4-E 400 LC4-E
25 kW 31 kW USA
Type PHM 38 ND PHM 38 ND BST40-225
Carb.-setting number 100197 100197 090298
Main jet 130 130 142,5
Needle jet AR 264 AR 264 689 X-6
Idling jet 50 50 45
Jet needle K 23 K 23 6G5
Needle clip pos. f. top 2. from top 2. from top 3. from top
Mixt. adj. screw open 1.5 turns 1,5 turns 2,25 turns
Throttle valve 50/1 50/1 –
Starting jet 45(50,55) 45(50,55) –
Performance restrictor slide stop 51mm – –
Repair manual KTM LC4

BASIC CARBURETOR SETTING

640 LC4-E, Adventure 640 LC4-E, Adventure 640 Duke
25 kW 36 kW 40 kW

Type BST40-225 BST40-225 BST40-225

Carb.-setting number 080298 090298 100299
Main jet 142,5 142,5 145
Needle jet 689 X-6 689 X-6 689 X-6
Idling jet 45 45 45
Jet needle 6G5 6G5 6G5
Needle clip pos. f. top 3. from top 3. from top 3. from top
Mixt. adj. screw open 2,25 2,25 2,25
Throttle valve – – –
Starting jet – – –
Performance restrictor slide stop 17mm – –
10-52D

TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001

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° 63°
Wheel base 1510 ± 10 mm (59,4 ± 0,4 in)
Seat high 955 mm (37,6 in) 935 mm (36,8 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)

STANDARD ADJUSTMENT - FORK STANDARD-ADJUSTMENT - SHOCK ABSORBER

400/640 LC4-E 640 LC4-E 400/640 LC4-E 640 LC4-E
SUPERMOTO SUPERMOTO
WP 0518V707 WP 0518V721 WP 0118V710 WP 0118V720
Compression adjuster 20 14 Compression adjuster 6 5
Rebound adjuster 12 14 Rebound adjuster 7 7
Spring 4,4 N/mm 5,0 N/mm Spring 66 / 260 75 / 260
Spring preload 6 mm 9 mm Spring preload 27 mm 15 mm
Air chamber length 150 mm 130 mm
Fork oil SAE 5 SAE 5