Technical Data - Tolerance, Wear Limits Of Engine - KTM 400 EXC AUS 2011 Repair Manual

TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
196
Camshaft - cam height
Exhausl 33.10 ... 33.30 mm (1.3031... 1.311 in)
Camshaft - cam height (Every 450 models)
Inlake
33.90 ... 34.10 mm (1.3346 ... 1.3425 in)
Camshaft - cam height (all 400 models)
Intake
33.90 ... 34.10 mm (1.3346 ... 1.3425 in)
Camshaft - cam heighl (All 530 models)
Intake
34.20 ... 34.40 mm (1.3465 ... 1.3543 in)
Valve
Intake sealing seal width
2.00 mm (0.0787 in)
Exhausl sealing seal widlh 2.00 mm (0.0787 in)
Run-out at valve plate S 0.05 mm (S 0.002 in)
Valve spring
Inlake minimum length (wilhoul valve spring seat) 46.5 mm (1.831 in)
Exhausl minimum length (withoul valve spring seat) 43.0 mm (1.693 in)
Valve spri ng seal 0.9 ... 1.0 mm (0.035 ... 0.039 in)
Cylinder/cylinder head - sealing area distortion S 0.1 mm (S 0.004 in)
Piston - diameter
Size I
94.93 ... 94.96 mm (3.7374 ... 3.7386 in)
Size II 94.94 ... 94.97 mm (3.7378 ... 3.739 in)
Cylinder - drill hole diameler
Size I
95 ... 95.012 mm (3.74 ... 3.74062 in)
Size II 95.013 ... 95.025 mm (3.74066 ... 3.74113 in)
Piston/cylinder - mounting clearance
Size I
0.040 ... 0.082 mm (0.00157 ... 0.00323 in)
Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in)
Wear limil
0.120 mm (0.00472 in)
Piston ring end gap
Compression ring S 1 mm (S 0.04 in)
Oil scraper ring S 1.2 mm (S 0.047 in)
Conrad bearing - axial clearance S 1.1 mm (S 0.043 in)
Conrod bearing - radial clearance
S 0.05 mm (S 0.002 in)
Crankshaft - run-oul on bearing pin S 0.16 mm (S 0.0063 in)
Crankshaft - external crank web dimension 63±0.05 mm (2.48±0.002 in)
Clulch facing disc - Ihickness
Outer 2.6 ... 2.7 mm (0.102 ... 0.106 in)
Innermosl
2.9 ... 3.0 mm (0.114 ... 0.118 in)
Clulch spring - length
43 ... 44.03 mm (1.69 ... 1.7335 in)
Thrust surface, clulch facing discs in ouler clutch hub S 0.5 mm (S 0.02 in)
Oil pressure regulalor valve
Minimum length of preload spring 23.5 mm (0.925 in)
Oil pump
External rotor/engine case clearance
S 0.20 mm (S 0.0079 in)
External rotor/internal rotor clearance S 0.20 mm (S 0.0079 in)
End play S 0.15 mm (S 0.0059 in)
Engine oil consumption S 20 mllh (S 0.68 flo oz.lhr)
Shift fork
Thickness al leaf
4.85 ... 4.95 mm (0.1909 ... 0.1949 in)
Shift shaft - play in sliding plale/shift quadranl 0.4 ... 0.8 mm (0.016 ... 0.031 in)
Transmission shaft - run-out S 0.06 mm (S 0.0024 in)
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
196
Camshaft - cam height
Exhausl 33.10 ... 33.30 mm (1.3031... 1.311 in)
Camshaft - cam height (Every 450 models)
Inlake
33.90 ... 34.10 mm (1.3346 ... 1.3425 in)
Camshaft - cam height (all 400 models)
Intake
33.90 ... 34.10 mm (1.3346 ... 1.3425 in)
Camshaft - cam heighl (All 530 models)
Intake
34.20 ... 34.40 mm (1.3465 ... 1.3543 in)
Valve
Intake sealing seal width
2.00 mm (0.0787 in)
Exhausl sealing seal widlh 2.00 mm (0.0787 in)
Run-out at valve plate S 0.05 mm (S 0.002 in)
Valve spring
Inlake minimum length (wilhoul valve spring seat) 46.5 mm (1.831 in)
Exhausl minimum length (withoul valve spring seat) 43.0 mm (1.693 in)
Valve spri ng seal 0.9 ... 1.0 mm (0.035 ... 0.039 in)
Cylinder/cylinder head - sealing area distortion S 0.1 mm (S 0.004 in)
Piston - diameter
Size I
94.93 ... 94.96 mm (3.7374 ... 3.7386 in)
Size II 94.94 ... 94.97 mm (3.7378 ... 3.739 in)
Cylinder - drill hole diameler
Size I
95 ... 95.012 mm (3.74 ... 3.74062 in)
Size II 95.013 ... 95.025 mm (3.74066 ... 3.74113 in)
Piston/cylinder - mounting clearance
Size I
0.040 ... 0.082 mm (0.00157 ... 0.00323 in)
Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in)
Wear limil
0.120 mm (0.00472 in)
Piston ring end gap
Compression ring S 1 mm (S 0.04 in)
Oil scraper ring S 1.2 mm (S 0.047 in)
Conrad bearing - axial clearance S 1.1 mm (S 0.043 in)
Conrod bearing - radial clearance
S 0.05 mm (S 0.002 in)
Crankshaft - run-oul on bearing pin S 0.16 mm (S 0.0063 in)
Crankshaft - external crank web dimension 63±0.05 mm (2.48±0.002 in)
Clulch facing disc - Ihickness
Outer 2.6 ... 2.7 mm (0.102 ... 0.106 in)
Innermosl
2.9 ... 3.0 mm (0.114 ... 0.118 in)
Clulch spring - length
43 ... 44.03 mm (1.69 ... 1.7335 in)
Thrust surface, clulch facing discs in ouler clutch hub S 0.5 mm (S 0.02 in)
Oil pressure regulalor valve
Minimum length of preload spring 23.5 mm (0.925 in)
Oil pump
External rotor/engine case clearance
S 0.20 mm (S 0.0079 in)
External rotor/internal rotor clearance S 0.20 mm (S 0.0079 in)
End play S 0.15 mm (S 0.0059 in)
Engine oil consumption S 20 mllh (S 0.68 flo oz.lhr)
Shift fork
Thickness al leaf
4.85 ... 4.95 mm (0.1909 ... 0.1949 in)
Shift shaft - play in sliding plale/shift quadranl 0.4 ... 0.8 mm (0.016 ... 0.031 in)
Transmission shaft - run-out S 0.06 mm (S 0.0024 in)