Removing The Balancer Shaft (200 Duke); Removing The Crankshaft (200 Duke); Work On Individual Parts; Work On The Left Section Of The Engine Case (125 Duke) - KTM 125 DUKE EU Repair Manual

16 ENGINE

16.3.65 Removing the balancer shaft (200 Duke)

16.3.66 Removing the crankshaft (200 Duke)

16.4

Work on individual parts

16.4.1

Work on the left section of the engine case (125 Duke)

–
Remove screw
–
Take off the lock washer.
–
Remove balancer shaft
305887-10
–
Mount special tool
Protecting sleeve (90129019000) (
–
Position the section of the engine case in a press.
–
Press out the crankshaft.
305888-10
–
Remove all dowels.
–
Remove lock ring
–
Remove shaft seal ring
–
Remove oil nozzle
–
Remove any sealing mass remnants and clean the engine case section thoroughly.
–
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
–
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
–
Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing all the way to the
stop or so that it is flush.
304769-10
Info
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
–
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
–
Mount the dowels.
.
1
.
2
.
1
p. 257)
.
1
of the shift shaft and
2
.
4
of the countershaft.
3
118