KTM 400 Owner's Handbook Manual page 35

ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft axial play ..................................................0,03 - 0,12 mm
run out of crank stud..................................max. 0,04 mm
Connecting rod bearing radial play ..................................................max. 0,05 mm
axial play....................................................max. 1,00 mm
Piston forged assembly clearance ....................................max. 0,12 mm
Piston cast assembly clearance ....................................max. 0,05 mm
Piston rings end gap compression rings.......................................max. 0,60 mm
oil scraper ring............................................max. 0,80 mm
Valves seat sealing intake ......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads................................max. 0,03 mm
valve guides diameter.................................max. 7,05 mm
Oil pump clearance outer rotor - housing ..................max. 0,20 mm
clearance outer rotor - inner rotor ..............max. 0,20 mm
Bypaß valve minimum spring lenght ..........................................25 mm
Clutch discs wear limit organic .................................................2,5 mm
Clutch springs minimum lenght ...........................34,5 mm (new 37 mm)
Transmission shafts axial play ......................................................0,1 - 0,4 mm
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop screw
AH screws oil pump
Hexagon screw camshaft gear
AH screw cylinder head top sect.
AH screw cylinder head top sect.
AH 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
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Screw plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
Crankshaft locking screw
Engine fastening screw
API: SF, SG, SH
TEMPERATURE
– 0°C
32°F
10W 40
10W 50
10W 60
M20x1,5
M12x1 LH thread
M18x1,5
M12x1,5
M6
M10
M6x25
M6x50/M6x55 (12.9)
M6x65/M6x70 (8.8)
M10
M10
M10
M22x1,5
M12x1,5
M12x1,5
M8x1
M10x1
M8x1
M12x1,5
M7x0,75
M12x1,25
M8
M8
M10
#
+
Engine oil
15W 40 Use only oil brands (Shell Advance Ultra 4), which meet qua-
lity requirements of API-classes SF, SG or SH (informations
15W 50 on bottles) or higher. Both, mineral and synthetic oils with
above specifications can be used.
15W 60
P
OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE
(0,001-0,005 in)
(0,002 in)
(0,002 in)
(0,04 in)
(0,005 in)
(0,002 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,080 in)
(0,001 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(1,36 in - new 1,45 in)
(0,004 - 0,016 in)
Loctite 242 +170Nm (125 ft.lb)
60 Nm (44 ft.lb)
Loctite 648 + 80 Nm (59 ft.lb)
50 Nm (37 ft.lb)
Loctite 242 + 8 Nm (6 ft.lb)
35 Nm (26 ft.lb)
8 Nm (6 ft.lb)
20 Nm (15 ft.lb)
8 Nm (6 ft.lb)
50 Nm (37 ft.lb)
40 Nm (30 ft.lb)
Loctite 242 + 40 Nm (30 ft.lb)
30 Nm (22 ft.lb)
20 Nm (15 ft.lb)
20 Nm (15 ft.lb)
10 Nm (7 ft.lb)
15 Nm (11 ft.lb)
10 Nm (7 ft.lb)
20 Nm (15 ft.lb)
20 Nm (15 ft.lb)
20 Nm (15 ft.Ib)
25 Nm 18 ft.lb)
40 Nm (30 ft.lb)
70 Nm (51 ft.lb)
! CAUTION !
- .
WEAR
33