technical data – engine 400/640 lc4-e, 640

technical data – engine 400/640 lc4-e, 640
TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2000
Type
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Quantity of engine oil
Engine oil
Primary ratio
Clutch
Transmission
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
400 LC4-E
640 LC4-E
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
398 ccm
624,6 ccm
89 / 64 mm
101 / 78 mm
10,8 : 1
11,0 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
(249/1)
IO 22° BTDC
EO 60° BBDC
IO 13° BTDC
EO 53° BBDC
IC 42° ABDC
EC 4° ATDC
IC 51° ABDC
EC 11° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0.20 mm Exhaust: 0.20 mm
Intake: 0.15 mm Exhaust: 0.15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
2 Eaton-Oilpumps
see table
2.1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
contactless DC- CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
DPR8 EA9
0.9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F)
electric starter, kick starter
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Connecting rod bearing
Cylinder 400
Cylinder 640
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pumps
Bypaß valve
Clutch
Camshaft
Transmission shafts
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm
run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm
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
clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm
Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop screw
Allan head screws oil pump
Allan head screws freewheel hub
Hexagon screw camshaft gear
Allan head screw cylinder head top sect.
Allan head screw cylinder head top sect.
Cylinder head screws
Collar nuts at cylinder base
Hexagon screw chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Hollow screws oil lines
Hollow screws oil lines
Jet screw clutch cover
Screw plug timing-chain tensioner
Counternuts valve adjusting screws
Crankshaft locking bolt
Engine mounting bolt
Engine mounting bolt
M20x1.5
M16x1.25 LH thread
M18x1.5
M12x1.5
M6
M6x12/M6x12.5
M10
M6x25/M6x65/M6x70 (8.8)
M6x50/M6x55 (12.9)
M10
M10
M10
M22x1.5
M12x1.5
M12x1.5
M8x1
M10x1
M8
M12x1.5
M7x0.75
M8
M8
M10
GEAR RATIOS
Primary
ratio
Transmission
1st gear
2nd gear
3rd gear
4th gear
5th gear
30:81
14:35
15:24
18:21
20:19
22:18
Original final
drive ratio
Available chain
drive sprockets
Available final
drive sprockets
15:45
16:42
17:38
17:42
15 t
16 t for chain
17 t 5/8 x 1/4"
38
40
42
45
48
API: SF, SG, SH
TEMPERATURE
–
10W 40
10W 50
10W 60
+
0°C
32°F
15W 40
15W 50
15W 60
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.
!
POOR OIL
NE-WEAR.
CAUTION
!
QUALITY OR MINOR QUANTITY EFFECT EARLY ENGI-
t
t for chain
t 5/8 x 1/4"
t
t
Loctite 242 + 170
80° C + 150
Loctite 648 + 80
50
Loctite 242 + 8
Loctite 648 + 18
Loctite 242 + 35
8
20
50
40
Loctite 242 + 40
30
20
20
10
15
10
20
20
25
40
70
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
(125
(132
(60
(35
(6
(13
(26
(6
(15
(37
(30
(30
(22
(15
(15
(7.4
(11
(7,4
(15
(15
(19
(30
(50
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
400 LC4-E
400 LC4-E
25 kW
31 kW
400 LC4-E
USA
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1.5 turns
50/1
45(50,55)
slide stop 51mm
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1,5 turns
50/1
45(50,55)
–
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
640 LC4-E, Adventure
640 LC4-E, Adventure
640 Duke
25 kW
36 kW
40 kW
BST40-225
080298
142,5
689 X-6
45
6G5
3. from top
2,25
–
–
slide stop 17mm
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25
–
–
–
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
BST40-225
100299
145
689 X-6
45
6G5
3. from top
2,25
–
–
–
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