2003ktm400-660lc4發(fā)動機維修手冊

ART.NR.:3.206.006-ART.NR.:3.206.006-400-660REPAIR維修手MANUALEDIRIPARAZIONEMANUALDE400-660LC4GENERAL

通用REMOVINGANDREFITTING拆卸及重新安裝發(fā)動DISASSEMBLINGTHE SERVICINGONINDIVIDUALASSEMBLINGTHE 組裝發(fā)動FUEL

燃油系TROUBLE TECHNICAL PERIODICMAINTENANCE定期計WIRING 接線ImportanImportantInformation/UpdatinginstructionsTobeabletocontinueusingtheexistingloose-leafrepairinstructions,simplyprintthefollowingpagesandinsertthemintheexistingrepairinstructions:15-18,20-28,32,35,40-54,64,66-69,73,77,79-81,84-207,219,280-314-319,323,378-RemovepageReplacebypageInsert1Cto2-2-1Dto2-2-2-5Cto2-2-6Dto2-3-3-4-4-4-5to4-4-5Dto4-5-1Ato5-5-1Dto5-5-5-5-14Dto5-5-21/5-5-21D/5-6-1Ato6-6-1Dto6-6-5Cto6-6-5Dto6-7-1to7-7-1Dto7-8-1Cto8-8-1Dto8-9-9-10-10-62Dto10-11-11-11-22Dto11-12-12-12-57Dto12-KTMREPAIRMANUALINLOOSE-LEAFFORMKTMSTORINGTHEREPAIRMANUALINTHEBINDER將維修手冊裝入活頁PuttheindexintothebinderPutthefrontpageoftherepairmanual(210x297mm)intothetransparentpocketprovidedforthispurposeontheoutsideofthebinder.–Putthespinelabel(170x45mm)intothetransparentpocketprovidedforthispurposeonthespineofthebinder.將書脊 Putthesummarylistofcontents(150x297mm)intothetransparentpocketprovidedforpurposeontheinsideofthebinderorinsertthispageonthebeginningofthe將內(nèi)容大綱(150x297mm)放入活頁夾內(nèi)特意因此提供的透明套中,或?qū)⒋搜b訂為手冊的首頁Theninserttheindividualchaptersofthemanualbetweenthesheetsoftheindexaccordingtothepagenumberprintedintherightbottomcornerofeachpage.Example:pageno.3- 3=chapter 5=page例:頁碼號3- 即3=章節(jié) 5=第5Allpageswithapagenumberthatbeginswiththedigit3,forexample,mustbeputundertheindexheading?Chapter3“. alTherespectiveheadingscanbeenteredinthelistofRepairRepairmanualKTMExplanationExplanation-Updating3.205.49-RepairManualBasicversionModelyear1998(Enginenumberwithfirstdigit?8“)（發(fā)動機號以"8"開頭3.205.73- UpdatingofRep.ManualLC4LC4維修手冊更新Modelyear (Enginenumberwithfirstdigit?9“)（發(fā)動機號以"9"開頭3.205.89- UpdatingofRep.ManualLC4LC4維修手冊更新Modelyear2000/20012000/2001年款(Enginenumberwithfirstdigit0and?1“)3.210.30- UpdatingofRep.ManualLC4LC4維修手冊更新Modelljahr20022002年(Enginenumberwithfirstdigit?2(發(fā)動機號以"2"開頭3.206.006-EUpdatingofRep.ManualLC4LC4維修手冊更新Modelljahr20032003年(Enginenumberwithfirstdigit?3（發(fā)動機號以"3"開頭:Specialtools,hydraulicclutch,Keihin特種工具，離合器，Keihin汽化technicaldetailsmodel2003,technical2003款詳細(xì)技術(shù)Maintenancescheduleandwiringdiagramsformodell2003款的計劃及接線EditionThisrepairmanualoffersextensivrepair-instructionsandisanup-to-dateversionthatdescribesthelatestmodelsoftheseries.However,therighttomodificationsintheinterestoftechnicalimprovementis monintheworkshophavealsonotbeenlisted.Wetakeitforgrantedthattherepairsaremadebyqualifiedprofesionallytrainedmechanics.Readthroughtherepairmanualbeforebeginningwiththerepair ESSENTIALTOAVOIDDANGERTOLIFEANDLIMB. PLIANCEWITHTHESEINSTRUCTIONSCANLEADTODAMAGEOFMOTORCYCLECOMPONENTSORRENDERMOTORCYCLESUNFITFORTRAFFIC!?NOTE”POINTSOUTUSEFUL更換零件時，只可使用原版KTM備件UseonlyORIGINALKTMSPAREPARTSwhenreplacingisperformedregularlyandprofessionally.只有進行規(guī)律，專業(yè) KTM ofachievementforitsqualitysystemISO9001isthebeginningofongoingtotalreengineeredqualityplanforabrighterKTMSportmotorcycleAG5230Mattighofen,Alldesignandassemblymodification CbyKTMSPORTMOTORCYCLEAG, AllREPLYREPLYFAXFORREPAIRWehavemadeeveryefforttomakeourrepairmanualsasaccurateaspossiblebutitisalwayspossibleforamistakeortwotocreepin.asfollows:Ifyoufindanyerrorsorinaccuraciesinoneofourrepairmanual–whetherthesearetechnicalerrors,incorrectorunclearrepairprocedures,toolproblems,missingtechnicaldataortorques,inaccurateorincorrecttranslationsorwording,etc.–pleaseentertheerror(s)inthetablebelowandfaxthecompletedformtousat0043/7742/6000/5349.NOTEtoEnterthecompleteitemno.fortherepairmanualincolumn1(e.g.:3.210.66-YouwillfindthenumberonthecoverpageorintheleftmarginoneachrightpageoftheEnterthecorrespondingpagenumberintherepairmanual(e.g.:5-7c)incolumnEnterthecurrenttext(inaccurateorplete)incolumn3byquotingordescribingtherespectivepassageofthetext.Ifyourtextdeviatesfromthetextcontainedintherepairmanual,pleasewriteyourtextinGermanorEnglishifpossible.EnterthecorrecttextincolumnYourcorrectionswillbereviewedandincorporatedinthenextissueofourrepairItemno.ofrepairCurrentCorrectAdditionalsuggestions,requestsorcommentsonourRepairManuals(inGermanorNamemechanic/shop Company/workMODELSWITHOUTFRAMECHANGINGTHEENGINEOILCHANGINGTHEOIL

2 2GENERALINFORMATION2RepairmanualKTMGENERALINFORMATION2RepairmanualKTMOILCIRCUIT油循環(huán) 4OILCIRCUIT660 660SMC油循環(huán) 5MODELSWITHFRAMECHANGINGTHEENGINEOIL更換發(fā)動機 6 6CHANGINGTHEOIL 7OIL 8SECONDARYAIR 9 10SPECIAL 11BLEEDINGOFTHEHYDRAULIC 1311AA212到2001年款為NOTETheengineoilchangeistobecarriedoutwhentheengineisstillwarm.注:更換機油應(yīng)在發(fā)動機溫?zé)釙r進行Anenginehavingbeenrunwarm,andtheengineoilinitareveryhotDONOTBURN–Placethemotorbikeonahorizontalsurface.Removethetwoplugs(1and2),anddrainoilintoacontainer.NOTE:Athirdplugwasinstalledinthe660SMCmodel.Tighteningtorque20Nm注:660SMC型中安有第三個插拴.固定扭矩力:20Nm ThescrewplugAmustnotberemoved,thisispartoftheby-passCleantheplugsthoroughlywithafireproofsolventandair,inordertoremovethemetalAfteralltheoilhasdrainedthrough,cleanraisedandflatfacesandinstallplugswithseals.Tightenplug1with30Nm(22ft.lb)andplug2with20Nm(15ft.lb).以30Nm(22英尺.磅)的扭矩力緊固插拴1,Removetheoildipstickattheclutchcover,pourinengineoilandreplacetheoildipstick. 油容量(從2003年款開始):1.5公534Changingtheoilfilter534Replacetheoilfilterwhenchangingtheengineoil.PressthefootbrakepedalandplaceascrewdriverorsimilarfootbrakepedalandstopperrollsothattheoilfiltercoverRemovebanjobolt3andthethreebolts拆除對接螺栓3和三個螺栓Removeoilfiltercover5andoil

Cleanfilterhousing,oilfiltercoverandsealingsurfaces.Checkoilductinoilfiltercoverifclogged.35356487PressthenewO-ring6intothegrooveofthefiltercovernecessaryfixwithgrease).Mountanewoilfilter7ontheconnectionpieceoftheoilfiltercoveranmountthewholeunit.NOTE:Frommodel2001onwardsthegasket8ismountedwithachangedfiltercover5.Ifthenewgasket8shouldbeusedonolderengines,thefiltercovermustbeflatregrindedorrenewed(seeTechnicalInfoNr.0201/30/01).RepairmanualKTM注:從2001年款開始,墊圈8安裝在新型的過濾器蓋RepairmanualKTMMountthreeboltsandtightenwith5Nm(4Mounthollowboltwithsealringsandtightenwith15(11安裝凹螺栓及密封圈，并以15Nm(1133. JASOT903–重新正確安裝量油尺然后再次拆除.油量線應(yīng)該在量油尺的兩個 小 只使用滿足或-于JASOT903MA標(biāo)準(zhǔn)的高質(zhì)量機油(可在其容 .RepairmanualKTMRepairmanualKTM油泵1使機油通過旁通閥門2通過濾油器3通過濾油器后,一條油路的油流向噴射器4 另一條油路的油順著主油路進入微型過濾器5以過濾掉所有雜質(zhì).過濾后的機油通過油路和荷蘭蓋,進入曲軸,來到連接桿軸承6然后滴入曲軸箱.另一個油泵7將機油吸出曲軸箱,泵入油線8來到第4檔和第5檔的齒輪.通過齒輪,機油進入油槽.定時鏈9穿過油槽將機油運送到氣缸蓋.通過孔bk機油進入控制軸bl及閥門5521387649Oilcircuit660SMC油路660另一條油路的油順著主油路進入第二噴射器45以過濾掉所有雜質(zhì).過濾后的機油通過油路和荷蘭蓋,進入曲軸,來到連接桿軸承6然后滴入曲軸箱.另一個油泵7將機油吸出曲軸箱,泵入油線8來到第4檔和第5檔的齒輪.通過齒輪,機油523874469進入油槽.定時鏈952387446911oil 警告 1AA1AA212fromModell2002uptoModell拆除兩個插銷1和2 小 43更換細(xì)43用相應(yīng)的工具拆除旋風(fēng)式濾清器3,手動旋出,讓機油從支擰出前管底端的插銷4,使油流出(適用至200065清潔前管的密封面565RepairmanualKTM 注意 RepairmanualKTM77以30Nm(23英尺.磅)的力扭緊插拴1,插拴2為20Nm,插拴4為312更換312拆除對接螺栓1和三個螺栓134265將新的O型圈134265 拆除轉(zhuǎn)向頭旁的插銷7,并使用潤滑劑注射 (見 孔B中冒出。 7B使用新的密封圈，重新安裝7B 8 8 .RepairmanualKTMRepairmanualKTM9Drainplug-frameoilModel20012138674Drainplug-frameoiluptoModel20005油泵1使機油通過旁通閥2通過濾油器9Drainplug-frameoilModel20012138674Drainplug-frameoiluptoModel20005第二空氣系統(tǒng)的功能特性當(dāng)排放閥打開，滾燙的排放氣體以高速通過排放口1排出。 oftheflowconditionsintheexhaustportandduetotheinfluenceexertedbytheentireexhaustsystemontheescagases,thepressureintheexhaustportdropstemporarilyDuringthesecyclicunderpressurephases,thesecondaryairvalve2opens,thusaddingoxygenoftheairtothehotexhaustgasesthroughpipe3.Athigherenginespeeds,thesecondaryairvalveinterruptstheoxygensupplytopreventoverheatingofthecatalyticconverter.Additionally,thesecondaryairvalvepreventstheexhaustgasesfromflowingbackintotheairfilterbox4.Whenthemotorcycleispushed(highunderpressureintheintakeport)thecontrolvalve(ASV)5interruptstheairflowintotheexhaustporttopreventexhaustdetonations.Thecontrolvalveiscontrolledviaacontrolpipe6.Thiscontrolpipetransmitstheunderpressurefromtheintakeport7tothecontrolvalve.Duringnormaloperation(slightunderpressureintheintakeport),thecontrolvalveisThereactionbetweentheoxygenoftheairandtheharmfulcomponentsoftheexhaustgases(CO-carbonmonoxide,HC-withtheSLS,allowsanadditionalsignificantreductionofpollutantemissions.667714253RepairmanualKTMElectronicRepairmanualKTMMaincomponentsoftheEPC –恒壓汽化微型開關(guān)（汽化器上TheEPCsystemisnotactivatedduringnormaloperationoftheItis,however,activatedassoonasthethrottleisfullyopenedataspeedof45-55km/hwhilethesecondorthirdgearareTheEPCcontroldeviceopensthesolenoidvalve,directinganappropriateflowoffreshairontotheuppersideoftheslidemembraneoftheconstant-pressurecarburetor,thusreducingtheopeningspeedoftheslide.Thismechanismsignificantlyreducestheexhaustgasemissionsofthevehicle.SOLENOIDSOLENOID SPECIALTOOLS 4

5 3755416 圖零件 1通用發(fā)動機工作2離合器3曲柄軸密封圈的安裝襯套?254磁電機分磁電機分離器5曲柄軸保護蓋6活塞的環(huán)形緊固 ?89活塞的環(huán)形緊固 ?95活塞的環(huán)形緊固 ?100活塞的環(huán)形緊固 ?101活塞的環(huán)形緊固 ?1027初級齒輪及離合器轂的分離8閥門安閥門安9閥門彈檢查閥門間隙的塞Loctite243 6ml樂泰（膠）243藍色Loctite648 20ml樂泰648用于混合通用螺釘?shù)陌恺X輪拆卸器[拉出器內(nèi)軸承拆卸器[拉出器 12-16內(nèi)軸承拆卸器[拉出器 18-23慣性輪固定扳手密封膠(Three-內(nèi)環(huán)NJ207的安裝工具（適用于LC4所有版本內(nèi)環(huán)NJ306的安裝工具（LC4-曲柄軸鏈條鏈離合器極限塞規(guī)?7,05油濾器油管注離合器的排放注射RepairmanualRepairmanualKTM213檢 離合器的油 213檢查離合器主缸需先拆除蓋子。為此，拆除螺釘和蓋子2墊3。在水平站位的主缸油位應(yīng)為上邊緣下4mm若需要，注入可生物降解的油SAE–針對離合控制，KTM–針對離合控制，KTM只使用可生物降解 –只可使用可生物降解的 5454及其下的橡膠墊3在離合器的副缸上，拆除排放接嘴4，安裝上裝有SAE10油的排放注射器5。注入油，直到主缸上的66 REMOVINGANDREMOVINGANDREFITTINGENGINE3RepairmanualKTMREMOVINGTHEENGINE拆卸發(fā)REMOVINGTHEENGINE拆卸發(fā) 2 4拆卸發(fā)21拆除兩個軟管夾1及軟管夾22134解開排放管上的4個彈簧33455687RepairmanualKTM687RepairmanualKTM211拆除兩個螺栓121133334545斷開電力啟動機的正線566772121Removetheleftaswellastherightengineretaining 43拆除螺栓3以及旋臂驅(qū)軸43A安裝發(fā)AWhenworkingonamodelwithanengineguardkeepinmindthatopeningAmustbelocatedontherightsideandfacetheengine.旋臂驅(qū)軸 100 74發(fā)動機安裝螺栓 40 30發(fā)動機安裝螺栓其他所有M6螺栓:其他所有M8螺栓:

70 5015 1110 710 725 1945 33 小 RepairmanualRepairmanualKTM 發(fā)動機順利運行后即可測試摩托車.測試后若有必要，調(diào)校所有DISASSEMBLINGDISASSEMBLINGTHEENGINE4分解發(fā)排放機 2拆除電子啟動 2REMOVINGTHECLUTCHRELEASELEVERANDTHEOIL 3REMOVINGTHEOIL 3REMOVINGTHEEPCWIRING 3REMOVINGTHEIGNITION(KOKUSAN4K- 3REMOVINGTHEIGNITION 5REMOVINGTHEIGNITION(KOKUSAN4K- 5REMOVINGTHEELECTRICSTARTER 6REMOVINGTHECYLINDERHEADTOP 7BLOCKINGTHEREMOVINGTHECAMSHAFTANDTHEAUTOMATIC 8REMOVINGCYLINDER 10REMOVINGCYLINDERAND 10REMOVINGENGINE 11REMOVINGCLUTCHANDPRIMARY 11REMOVINGTHEOIL 13REMOVINGTHETIMINGCHAINANDTHETIMING 14REMOVINGTHECLUTCHRELEASE 14PARTINGOFENGINE 15REMOVINGTHESHIFT 15REMOVINGTHETRANSMISSION 17RepairmanualKTMREMOVINGTHERepairmanualKTM12拆除螺栓1和墊圈.然后拆除變速桿及其后的V124343frommodell20024uptomodel35RepairmanualKTM5RepairmanualKTM1拆除離合器分離桿及油122223拆除油344拆除EPC線44Removingtheignition(Kokusan4K-Undo4boltsandremovetheignitioncoverwiththestatorincl.Undo6boltsandremovestarterflangeincl.22 Toavoiddistortionofthecrankweb,nevermountthecrankshaftlockingbolttosteadytheflywheel.1Puttheprotectioncover1ontothecrankshaft1Pullofftheflywheelandtakethewoodruffkeyoutofthe RepairmanualKTMNeveruseahammeroranyothertoolontheRepairmanualKTMRemovingtheignitionUsethecrankshaftlockingbolttoblocktheUnscrewcollarnut(LHthread)andremovespringTwistthecrankshaftlockingboltoutuntilthecrankshaftisnolonger Neveruseahammeroranyothertoolontheflywheeltoavoidlooseningofthemagnets.Removingtheignition(Kokusan4K-Undothe4boltsandtakeofftheignitioncovertogetherwiththeUsethecrankshaftlockingbolttoblocktheUndothecollarnut(LHthread)andremovethespringMounttheextractorandpullofftheTakethewoodruffkeyoutoftheFinally,twistoutthecrankshaftlockingboltuntilthecrankshaftisnolongerblocked. Neveruseahammerorsimilartoolontheflywheeltopreventlooseningofthemagnets.123RepairmanualKTM123RepairmanualKTMPullthereductiongear1offthebearingRemovebothneedlebearings2andpullthebearingbolt3outoftheenginehousing.54Removethefreewheelgear4andtheneedlebearing541Removingthecylinderheadtop1Unscrewplug1withgasketandremovepressurespringfromautomatictensioner.23Undothe4hoseclampsandremovebothhoses(2and234Removeall6bolts4togetherwiththesealringsandtakeoffbothvalvecoverstogetherwiththegaskets.465Removethehexagonnut5andtakeofftheretainingbracketofthesolenoidvalve665NOTE:AretainingbracketisonlyusedinengineswithRemoveall11bolts.Thenremovethecylinderheadtop Whenremovingcylinderheadtopsectiondonotchockit.Thiswoulddamagethehousingofthewaterpump.NOTE:ThecontrolvalveofSLSmodelscanberemovedafterunngtheboltsofthecylinderheadtopsection.APullwaterpumpupwardandsimultaneouslyturnANOTE:WhengrooveAintheHHboltisvertical,thewaterpumpcanbepulledupwardandtakenoutofthecylinderheadwithouttheapplicationofforce.BBlockingtheBTurnthepistontopositionTDC(markBmustcoincidewiththeplanesurfaceofthecylinderhead).UndothecrankshaftlockingboltRemovethecopperdisc21NOTE:SameenginesareequippedwithanormalboltM8x16andacopperwasher8x12x1insteadofthecrankshaftlockingbolt21ReinsertcrankshaftlockingboltbyIftheboltdoesnotslidesmoothlyintoitsbore,slightlymovethecamshaftgear(ifcylinderheadtopsectionismountedturntheitsbore.Tightencrankshaftlockingboltwith20 UNDERNOCIRCUMSTANCESAPPLYFORCETOboltINCRANKSHAFTLOCKINGBOLTASTHISWILLDAMAGETHECRANKSHAFT.3Removingthecamshaftandtheautomatic3645RepairmanualKTMRemovethetwobolt4andtakeoffthe645RepairmanualKTM1Usingascrewdriver,levercirclip1outofthe12Tiltcamshaftandremoveneedlebushing2Whiletilted,pullcamshaftfromcamshaftgearandremovetogetherwithgroovedballbearingandcirclip.Takethecamshaftgearoutofthetimingchainasindicatedinthe132Removingcylinder1324Unscrewthe4collarbolts4anddetachcylinderheadwith455Unscrewthe4collarnutsatthecylinderbaseRemovecylinderand6Whenworkingonanenginewithamicrofilter,removetheAH66beforetakingofftheRepairmanualKTMDisconnecttheoilhoseattheclutchcoverRepairmanualKTMRemovetwowirecirclipsandpresspistonpinoutofRemove1Removingengine1RemovethesprocketfromtheRemovethedistancebushingfromtheNOTE:Ifthegear-boxandtheclutchoftheengineareingoodcondition,throwitintogearinordertoblockthetake-offshaft(frictionalconnectiontotheblockedcrankshaftispresent).Ifthetake-offshaftcannotbeblockedasdescribedabove,achainsprocketholdermustbeappliedfortheremovalofthechainsprocketnut.RemovingclutchandprimaryRemovethe11boltsanddetachclutchcoverwith3Unscrewthebolts3oftheclutchcrosswisetopreventtheclutchdiscsfromjammingwhenthespringsarerelievedoftension.3Removebolts,springretainerandRemovepressurecapwithpush2RemovethediscpackageandtaketheO-ring2alsoofftheinnerclutchhub.21Releasethelockwasheroftheinnerclutch1Puttheclutchholder1ontotheinnerclutchhubandundothehexagonnut(seeillustration).RemovetheclutchTakethehexagonnut,thelockwasherandtheinnerclutchhuboffthemainshaft.Trytoturntheouterclutchhubinbothdirectionstochecktheabsorbingelements.Deadtravelineitherdirectionisinadmissible.2Taketheouterclutchhubandtheneedlebearing2off233RepairmanualKTMUnscrewhexagonnutofprimarygearwheelRepairmanualKTMFitextractorforprimarygearandpulloffprimaryRemovethebalancershaftfromthebearingby312Removingtheoil312NOTE:ThefollowingproceduremustalwaysbeperformedonbothoilRemovethelockingwasherRemovestopdisc2andtheoilpumpgear4545786786NOTE:Forbetteraccesstobolt7removebolts8andtakeofftheretainingbracket.123Removingthetimingchainandthetiming123Removeallanheadbolt1andremovetimingchainguidefromtheUnscrewflat-headscrew2andremovetimingchainUnscrewallanheadbolt3andremovetimingchainsecuringInserttimingchainintotheclutchcompartmentoftheenginehousinganddisengagefromtiminggear.44Withdrawthetimingpinionfromcrankshaftwitha2-jawTakethewoodruffkeyofthetiminggearoutofthe56Removingtheclutchrelease56Removebolt(s)5andtakeofftheretaining87Pulltheclutchreleaseshaft7outofthe87RepairmanualKTMRepairmanualKTMPartingofengineLoosenthecrankshaftlockingTipignitionsideupwardsandremoveallthehousingReleaseenginemountonenginerepairLiftrighthandhousinghalfwithsuitabletoolsbearingonthebossesprovided,orpartwithafewlightplasticmalletblowsagainstthecountershaft. Leveringapartwithascrew-driverorsimilartoolmustbeavoided,sincethesealingsurfacesareeasilydamaged.1212TaketheO-ring2offtheRemovethecrankshaftfromthebearingby34Taketheinnerring3oftherollerbearingandtheO-ringbelow34offthe65Removingtheshift65Pushbackslideplate5andpullshiftshaftoutofthekickstarter211RepairmanualKTMRemovethe3bolts1anddetachthe211RepairmanualKTM433Pullouttheshiftrails3andswingtheshiftforksaside,taking433oftheshiftrolls6onthedrivingpinsoftheshiftPulltheshiftroller4outofthebearing56Taketheshiftforks5togetherwiththeshiftrolls6outof56engineengineNOTE:AlthoughthecountershaftshiftforksareRemovingthetransmissionPullbothtransmissionshaftsoutofthebearingenginehousingtogetherwiththeneedlebearingandthestopdisc.NOTE:Arollerbearingwasinstalledinthe660SMCmodel,thusastopdiscisunnecessary.1Removingthekickstarter1PutkickstarterontokickstartershaftandholdinthisUnscrewstopbolt1andrelievestarterspringtensionbyreleasingthekickstarter.RemovekickstartershaftassemblyfromTakethestartergearoutofthehousingbagtogetherwiththeneedlebearingandthestopdiscs.NOTE:Whenanengineiscompleyoverhauleditis thatallgaskets,shaftsealrings,O-ringsand,possibly,allbearingsareSERVICINGSERVICINGONINDIVIDUALCOMPONENTS5WORKINGONTHERIGHTHOUSING 3WORKINGONTHELEFTHOUSING 5 6MEASURINGANDADJUSTINGOFCRANKSHAFTAXIAL 7CHECKINGTHE 7MOUNTINGINSTRUCTIONSFORPISTON 8PISTONRINGEND 8MEASURINGPISTONANDCYLINDER,THEPISTONFITTING 8CYLINDER–NIKASIL 9RECOATEDDISASSEMBLINGTHECYLINDERHEADANDTHECOMPONENTSFOR 10DISASSEMBLINGTHECYLINDERHEADTOPSECTIONCHECKINGCOMPONENTSFOR 11PRE-ASSEMBLINGTHECYLINDERHEADTOP 11CHECKINGTHECOMPONENTSOFTHETIMINGMECHANISMFOR 12DISASSEMBLINGTHECAMSHAFTANDCHECKINGCOMPONENTSFOR 12PRE-ASSEMBLINGTHE 12AUTOMATIC 13PREASSEMBLYOFAUTOMATIC 13DISASSEMBLINGTHEOILPUMPSANDCHECKINGRepairmanualKTMCOMPONENTSRepairmanualKTM 14OILLINES 14 15OILLINES(MODELSWITHFRAME 15CHECKINGTHEKICKSTARTERCOMPONENTSFOR 16 16CLUTCH 16REPLACINGABSORBINGELEMENTSOFTHEOUTERCLUTCH 16CHECKINGTHECLUTCHCOMPONENTSFOR 17CHECKINGTHESHIFTMECHANISMCOMPONENTSFOR 18PREASSEMBLYOFSHIFT 18SHIFTMECHANISM 19BALANCER 19DISASSEMBLINGANDREASSEMBLINGTHEWATER 19IMPORTANTNOTEREGARDSWORKINGON 20ASSEMBLINGTHEMAIN 20ASSEMBLINGTHECOUNTER 21REMOVINGTHEINTERMEDIATE 22CHECKINGTHE 22REPLACINGTHEFREEWHEEL 22ELECTRICSTARTER 22IGNITION(KOKUSAN4K- 23CHECKINGTHESTATORANDTHEPULSEGENERATOR(KOKUSAN4K- 23REPLACINGTHESTATOR(KOKUSAN4K- 23IGNITION 24CHECKINGTHESTATOR 24REPLACINGTHESTATOR 24CHECKINGTHESTATOR(KOKUSAN4K- 25REPLACINGTHESTATOR(KOKUSAN4K- 25IMPORTANTNOTEREGARDSWORKINGONENGINEReadthroughthefollowingsectionbeforecommencingwork.Thendeterminetheassemblysequencesothattheenginehousinghalvesonlyneedtobeheateduponcebeforereplacingthebearings.Havingfirstremovedthedowels,inordertoexpelthebearingsorremovethemwithlightmalletblows,thehousinghalvesmustbeplacedonasuitablylargeplanesurface,supportingthewholeofthesealingsurfacewithoutdamagingit.Awoodenpanelisbestusedasabase.Bearingsorshaftsealringsshouldnotbehammeredintotheirseats.Ifnosuitablepressisavailable,useasuitablemandrelandhammertheminwithgreatcare.Coldbearingswillpracticallydropintotheirseatsatanenginehousingtemperatureofapprox.150°C.Aftercooling,shouldthebearingsfailtolockinthebore,theyareboundtorotateafterwarming.Inthateventthehousingmustbereplaced.45Workingontherighthousing45Removeshaftsealringsandheathousinghalftoapprox.150°Cbymeansofahot-plate.RollerbearingofcrankshaftProceedasforlefthousingCylinderrollerbearingofcountershaftfrominsideasfarasstop.33162Usecompressedairtocleanalloilducts.Ensurethattheoil33162CountershaftsealringPressinnewshaftsealringfromoutsideuntilCrankshaftsealringPressinnewshaftsealringfromoutsideuntil886Needlebearingofmainshaft6RepairmanualKTMPulloldbearingfrombearingseatusingbearingextractoandinsert.Inordertoapplythebearingextractorinanverticalposition,asteelplate(seespecialtools)mustbelaidonthesealingareaofthehousing.ThebearingextractorjawsshouldfitascloseaspossibleupRepairmanualKTM7AOilnozzle7AForthecleaningoftheoilnozzleandtheoilductsimplyblowitthroughwithcompressedairfromthenozzleside.Iftheoilnozzleisdisassembled,secureitwithLoctite243whenmountingagain.ThencheckthelubricationboreAofthecrankshaftrollerbearingfreeAfterthecasehalfhascooleddown,checkbearingsforsecureNeedlebushesoftheclutchPullouttheneedlebushesoftheclutchdisengagementwithagearpullerandinsertfromthehousinghalf.OiltheneedlePressthefirstneedlebushAtoPressthesecondneedlebushBsothatitis45132Workingonthelefthalfof45132Removeshaftsealringsandheathousinghalftoapprox.150°Cbymeansofahot-plate.NeedlebearingofcountershaftPressinnewneedlebearingfrominsideuntilShaftsealringofkickstartershaftPressinnewshaftsealringfromoutsidewithsealinglipfacinginwardsuntilflush.Groovedballbearingofthebalancershaft66897Useanextractorandinserttoremovethegroovedball66897ShaftsealringofcrankshaftPressinnewshaftsealringfromoutsidewithsealinglipfacinginwardsuntilflush.RetainingplateformainshaftgroovedballbearingIftheretainingplatehasbeenremoved,useLoctite243forthetwocountersunkboltsduringassembly.Usecompressedairtocleanalloilducts.Ensurethattheoilductsarenotclogged.RollerbearingofcrankshaftFromoutsidepresscrankshaftrollerbearinginwardsusingasuitable3Pressinnewrollerbearingfrominsideuptothe3GroovedballbearingofmainshaftPressinnewgroovedballbearingfrominsideupto Donotuseforcewhenpressingthegroovedballbearingagainsttheretainingplate5toavoidabendingoftheplate,whichwouldresultinexcessiveaxialplayofthemainshaft.NeedlebearingofkickstartershaftPressinnewneedlebearingfrominsideuntilBypassTestvalvepiston,tightfitandpressurespringforMinimumlengthofthepressurespringbk:23,5RepairmanualRepairmanualKTMAEnsurethatneitherthelubricationboreoftherollerbearingAnortheoilductsoftheoilpumpsareclogged.AAfterthehousinghalfhascooleddown,checkbearingsfortightFinally,insertbothdowelssothatthedowelwithinternal15.4mmismountedattherear(swingarmIftheconrodbearingisreplaced,takecaretoproperlypositionthecrankpin.TheboresofthecrankwebBandcrankpinCmust Ifthecrankpinispressedinthewrongposition,theconrodbearingisdinsufficientlyornotatallwithengineoil,whichresultsBEARINGIfthecrankshaftiscontinuedtobeused,checkcrankshaftjournalsfortheouterendofthejournalsforrunoutwithadialgauge.runoutofcrankshaftjournals:max.0.04mm(0.0016radialclearance:max.0.05mm(0.0019in)axialclearance:max.1.00mm(0.04Ifthecrankshaftrollerbearingsarereplaced,theinnerringsonthecrankshaftshouldalsobechanged.Heatspecialtoolonaheatingpaduptoapprox.150°Candslipitonobtainagoodheattransferandpulltheinnerringoffthecrankshaft.Tomountthenewinnerring,heatthespecialtoolagaintoapprox.150°C,engagetheinnerringandslipitonthecrankshaftjournalInordertosafelypressonnewrings,amiddlepanelshouldbeinsertedbetweenthecrankshaftwebs.Thispanelshouldbebigenoughtobesupportedonbothsides,sothatthecrankshaftliesfreeandaccessible.NOTE:BecauseLC4-Emodelshavedifferentdiametersofinnercrankshaftbearingrings,itisnecessarytohavebothspecialtools(584.29.037.040and584.29.037.043). Neverclampthecrankshaftwithacrankshaftjournalorwebinthevice,andnevertrytoknocktheinnerringfree.Thecrankshaftwebsmaybecompressedtherebymakingthecrankshaftunuseable.MeasuringandadjustingofcrankshaftaxialShouldthecrankshaft,enginehousing,orarollerbearingbereplaced,theaxialclearanceofthecrankshaftshouldalsobeThehousingshouldbelaidinsideupwards,thenmeasurethedistancefromthesealingareatotheinnerringsoftherollerbearings.Notethereadingsandthenaddon0.3mmtoallowforgasketthickness.Measurethecrankshaftattouchingpointsandthensubtractthemeasuredvaluefromthehousingdimensions.Thisfigurewillbetheaxialplayofthecrankshaft,whichshouldbe0.03-0.12mm(0.001-0.005in).Left-handhousing 33.0mm1.300( +32.8mm1.290( +0.3mm0.012(Totalhousing =66.1mm2.602(Crankshaft –65.8mm2.590(Axialplay =0.3mm0.012(Thecompensatingwashersshouldbeequallydistributedbetweenthetwosidesofthecrankshaft.Inourexample,onecompensationwasher(0.1mm/0.004in.)mustbemountedoneitherside.CheckingtheReplacethepistoninthecaseofexcessiveoilconsumptionorgroovesinthepistonskirt.IfreinstallingtheoldpistonperformPistonbearingsurface-checkforPistonringgrooves-thepistonringsmustmoveeasilyinthegroove.Oldpistonringsorsandpaper(400grit)maybeusedtocleanthepistonringgrooves.Pistonrings-checkfordamageandendgap(seeThepistonpinmustmovefreelyinthepistonwhenmounted.Ifthepistonpinchangeditscolorbadlyorshowsrunningtraces,itmustbereplaced.Insertpistonpinalsointotheconrodandcheckfor umclearanceintheconrodeye0.08mm(0.003RepairmanualKTMNOTE:Wheninplace,thepistonpinmaynothaveanyplay.RepairmanualKTMMountinginstructionsforpistonInserttheoilscraperringinthelowerringgroove.Sideofringmarkedfacingpistonhead.ringgroove.Sideofringmarkedfacingpistonhead.Insertthecompressionring(rectangularring)intheupperpistonringgroove(thesurfacemarkedmustbeontop).?89?95?101?101CompressionOOONTaperedNOilscraperPistonringendInsertpistoringintothecylinderandadjust.Pistonringmustbeapprox.10mm(1/2inch)fromtopofcylinder.Compressionrings:max.0.60mm(0.023in)Oilscraperring: max.0.80mm(0.03in)Iftheendgapisgreatercheckpistonandcylinderforwear.Ifpistonandcylinderweararewithinthepermittedtolerancelimits,replacethepistonring.xyMeasuringpistonandcylinder,determiningthepistonxyInordertodeterminethewearofthecylinder,measurethecylindercenteroftherunningareawithamicrometer.Measurethediame