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KTM 400 EXC Racing Manual

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ENGLISH
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TECHNICAL DATA – ENGINE »
ENGINE 250 EXC 400 EXC 450 SX 450 XC 450 EXC 525 SX 525 XC 525 EXC
Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft
Displacement 250 cc 398 cc 449 cc 449 cc 448 cc 510 cc
Bore/Stroke
75 / 56.5 mm
89 / 64 mm
95 / 63.4 mm 95 / 63.4 mm
89 / 72 m 95 / 72 mm
Ratio 12 : 1 11 : 1 12 : 1 12 : 1 11 : 1 11 : 1
Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91)
Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Camshaft 5532 595/0121 590/5521 590/5521 590/5521 590/5521
Valve diameter Intake 28 mm 35 mm
35 mm (Titan)
35 mm 35 mm 35 mm
Valve diameter Exhaust 24 mm 30 mm
30 mm (Titan)
30 mm 30 mm 30 mm
Valve clearence cold Intake 0.10 - 0.15 mm (0,004 - 0,006 in)
Valve clearence cold Exhaust 0.10 - 0.15 mm (0,004 - 0,006 in)
Crank shaft bearing 2 cylinder roller bearing
Connecting rod bearing needle bearing
Top end bearing bronze bushing
Piston alluminium alloy cast cast forged forged cast forged
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication pressure circulation lubrication with two rotor pumps
Engine oil full synthetic oil (Motorex Power Synt 4T 10W/50)
Quantity of engine oil 1.25 liters
Primary ratio straight geared spur wheels 33:76 Z
Clutch multi disc clutch in oil bath
Transmission claw shifted 6-speed 6-speed 4-speed 6-speed 6-speed 4-speed 6-speed 6-speed
Gear ratio
1st Gear
14:38 14:34 16:32 14:34 14:34 16:32 16:32 14:34
2nd Gear 16:36 17:31 18:30 17:31 17:31 18:30 18:30 17:31
3rd Gear 19:34 19:28 20:28 20:28 19:28 20:28 20:28 19:28
4th Gear 21:32 22:26 22:26 22:26 22:26 22:26 22:26 22:26
5th Gear 23:30 24:23 – 24:24 24:23 – 24:24 24:23
6th Gear 22:25 26:21 – 21:18 26:21 – 21:18 26:21
Ignition system contactless DC-CDI ignition with digital advanced system by KOKUSAN
Generator 12V 150W – 12V 150W – 12V 150W
Spark plug NGK DCPR 8 E
Spark plug gap 0.6 mm (0.02367 in)
Cooling system liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
Cooling liquid 1 liter, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
Starting equipment kick - electric starter kickstarter kick - electric starter kickstarter kick - electric starter
Engine oil
Only use fully synthetic engine oils that meet the JASO MA quality require-
ments (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem-
peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE-WEAR.
0°C
32°F
10W/50
5W/40
JASO T903 MA
TEMPERATUR
… 57 …


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