KTM LC4 ADVENTURE R 640 2000 - Engine Tightening Torques; Engine Assembly Clearances

ENGLISH
37
Crank shaft axial play .....................0,03 - 0,15 mm (0,0012 - 0,0059 in)
run out of crank stud ...................max. 0,08 mm (0,0031 in)
Connecting rod 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 rings 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 lenght..............................25 mm (0,985 in)
Clutch clutchspring lenght .... min. 34,5 mm (1,36 in), new 37 mm (1,458 in)
Wear limit organic............................min. 2,5 mm (0,0985 in)
Cam shaft 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 !
POOR 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
#
Hexagon nut at primary gear M20x1,5 Loctite 242 + 170Nm (125 ft.lb)
Hexagon nut flywheel M16x1,25 LH thread 80°C + 150 Nm (110 ft.lb)
Hexagon nut for inner clutch hub M18x1,5 80 Nm (59 ft.lb)
Kickstarter stop screw M12x1,5 50 Nm (37 ft.lb)
Allen head screws oil pump M6 Loctite 242 + 8 Nm (6 ft.lb)
Hexagon screw camshaft gear M10 Loctite 242 + 35 Nm (26 ft.lb)
Allen head screws outer race M6x12/M6x12,5 Loctite 648 + 18 Nm (13 ft.lb)
Allen head screw cylinder head top sect. M6x50/M6x55 (12.9) 20 Nm (15 ft.lb)
Allen head screw cylinder head top sect. M6x25/M6x65/M6x70 (8.8) 8 Nm (6 ft.lb)
Cylinder head screws M10 50 Nm (37 ft.lb)
Collar nuts at cylinder base M10 40 Nm (30 ft.lb)
Hexagon screw chain sprocket M10 Loctite 242 + 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 M8 25 Nm (18 ft.lb)
Hollow screws oil lines M8x1 10 Nm (7 ft.lb)
Hollow screws oil lines M10x1 15 Nm (11 ft.lb)
Jet screw clutch cover M8 10 Nm (7 ft.lb)
Screw plug timing-chain tensioner M12x1,5 20 Nm (15 ft.lb)
Counternuts valve adjusting screws M7x0,75 20 Nm (15 ft.lb)
Engine fastening screw M8 40 Nm (30 ft.lb)
M10 70 Nm (52 ft.lb)
TIGHTENING TORQUES - ENGINE