Replacing The Roller Bearing - KTM 2003 950 Adventure Repair Manual

1
A
A
1
2
4
3
6

Replacing the roller bearing

– Remove all bearing locking bolts
A
1
NOTE:
– Additional oil jets are installed from the 2005 model; they should
– the output-end antifriction bearing on the countershaft mounted by
1
– Remove all shaft seal rings and the dowel pins from the case halves.
Heat both case halves evenly in an oven at 150° C; the roller bearings
will fall out of the case by themselves. If any roller bearings should be
left in the case, tap the case lightly on a flat wooden surface.
NOTE: the shift shaft bearing
tool 600.29.043.030, although this bearing is usually highly resistant
to wear.
– Replace all of the roller bearings. The new roller bearings can be
NOTE: the shift shaft bearing
pressing tool 600.29.043.030.
– Press in the shaft sealing ring
– Press in the shaft sealing ring for the countershaft
5
– Press in the shaft sealing ring for the shift shaft
– Apply Loctite 243 to all bearing locking bolts
– Remove all of the oil jets, blow compressed air through the oil ducts
7
NOTE:
– Size "60" jets are used to lubricate the timing chains, size "90" jets
– Starting with engine number 2-600-02549, a size "30" reducing
also be removed to prevent them from being bent.
KTM does not have a sealing from the 2005 model. An antifriction
bearing with a one-sided sealing is provided for repair; to keep it
from blocking the lubrication, the open side must point towards the
inside (towards the center of the housing).
2
inserted by hand until flush as soon as the case temperature has
reached approx. 150° C. The roller bearings should fit tightly after
cooling down. Use a mandrel to carefully press in any bearings that
are not flush with the surface.
the special tool 600.29.043.010.
using the special tool 600.29.043.020.
the special tool 600.29.043.030.
and screw the oil jets back on.
for the piston cooling.
sleeve is screwed into the outer bore
6
housing half to supply the clutch and the pushrod with oil. This jet
should be retrofitted in all engines of an earlier make - see Technical
Information, Chapter 1.
from both case halves.
1
must be pressed out with the pressing
must be pressed in flush with the
2
for the push rod until flush using
3
4
until flush using
5
and tighten to 6 Nm.
1
on the outside of the left
7
5-2
until flush