Checking The Cylinder Head; Installing Valves - KTM 450 EXC-R EU Repair Manual

30/ENGINE - WORK ON INDIVIDUAL PARTS

Checking the cylinder head

0 0 A
A

Installing valves

Check the exhaust valve guides using special tool
Limit plug gauge (59029026006) (
» If the special tool is easy to insert into the valve guide:
Change the valve guide and valve.
Check the intake valve guides using the special tool.
Limit plug gauge (77029026000) (
» If the special tool is easy to insert into the valve guide:
Change the valve guide and valve.
200192-10
Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
Change the cylinder head.
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041000) (
Cylinder/cylinder head - sealing area
distortion
» If the measured value does not equal the specified value:
Change the cylinder head.
400375-10
Check sealing seat
Valve
Sealing seat width, intake
Valve
Sealing seat width, exhaust
» If the measured value does not equal the specified value:
Machine the valve seat.
Blow though all oil holes with compressed air and check that they are clear.
400373-10
Check parts for damage and wear. Replace damaged or worn parts.
Mount new valve stem seals. Position the lower valve spring retainers.
Mark the valves according to their position in the engine.
Mount the spring and spring retainer.
200188-10
Tension the valve springs with a special tool.
Valve spring mounter (59029019000) (
Valve spring mounting device (78029060000) (
200187-10
P. 179)
P. 181)
P. 179)
0.1 mm ( 0.0039 in)
of the valves.
1.5 mm (0.06 in)
2 mm (0.08 in)
P. 178)
.
P. 183)
88