TECHNICAL DATA – ENGINE KTM 640 LC4 e ‘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 DPR8EA-9
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 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
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear M20x1.5 Loctite 242 + 170 Nm (125 [Link])
Collar nut flywheel M16x1.25 LH thread 80° C + 150 Nm (132 [Link])
Hexagon nut for inner clutch hub M18x1.5 Loctite 648 + 80 Nm (60 [Link])
Kickstarter stop screw M12x1.5 50 Nm (35 [Link])
Allan head screws oil pump M6 Loctite 242 + 8 Nm (6 [Link])
Allan head screws freewheel hub M6x12/M6x12.5 Loctite 648 + 18 Nm (13 [Link])
Hexagon screw camshaft gear M10 Loctite 242 + 35 Nm (26 [Link])
Allan head screw cylinder head top sect. M6x25/M6x65/M6x70 (8.8) 8 Nm (6 [Link])
Allan head screw cylinder head top sect. M6x50/M6x55 (12.9) 20 Nm (15 [Link])
Cylinder head screws M10 50 Nm (37 [Link])
Collar nuts at cylinder base M10 40 Nm (30 [Link])
Hexagon screw chain sprocket M10 Loctite 242 + 40 Nm (30 [Link])
Oil drain plug M22x1.5 30 Nm (22 [Link])
Magnetic plug M12x1.5 20 Nm (15 [Link])
Plug bypass valve M12x1.5 20 Nm (15 [Link])
Hollow screws oil lines M8x1 10 Nm (7.4 [Link])
Hollow screws oil lines M10x1 15 Nm (11 [Link])
Jet screw clutch cover M8 10 Nm (7,4 [Link])
Screw plug timing-chain tensioner M12x1.5 20 Nm (15 [Link])
Counternuts valve adjusting screws M7x0.75 20 Nm (15 [Link])
Crankshaft locking bolt M8 25 Nm (19 [Link])
Engine mounting bolt M8 40 Nm (30 [Link])
Engine mounting bolt M10 70 Nm (50 [Link])

BASIC CARBURETOR SETTING

640 DUKE
40 kW

Carburetor BST40-225
Carburetor setting number 100299
Main jet 145
Needle jet 689 X-6
Idling jet 45
Jet needle 6G5
Needle position from top 3 rd
[Link]. screw open 2,25 turn

# API: SF, SG, SH

TEMPERATURE
s – 0°C
32°F
+ g
10W 40 15W 40
10W 50 15W 50
10W 60 15W 60

Engine oil
Use only oil brands (Shell Advance Ultra 4), which meet
quality requirements of API-classes SF, SG or SH (infor-
mations on bottles) or higher. Both, mineral and syn-
thetic oils with above specifications can be used.
! CAUTION !
POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-
WEAR.