Replacing The Pilot Bushing; Checking The Damper - KTM 400 EXC AUS 2011 Repair Manual

04LSHOCK ABSORBER, SWINGARM
Replacinllhe pilot bushinl
200798-10
Checkinllhe damper
200811-10
- Disassemble the seal ring retainer. (or p. 47)
- Press pilot bushing. out of seal ring retainer. using the special tool.
I
Press drift (Tl504)
(or
p. 266)
- Slide the new pilot bushing. onto the special tool.
I
Press drift (Tl504) (or p. 266)
- Position the pilot bushing in the seal ring retainer using the special tool.
I
Press drift (Tl504)
(or
p. 266)
- Support seal ring retainer. with the sleeve. of the special tool. Press the pilot
bushing all the way in.
I
Assembly tool (Tl50S)
(or
p. 266)
- Lubricate the special tool.
Shock absorber oil (SAE 2,5) (50180342S1)
(or
p. 250)
Calibration pin (Tl205) (or p. 263)
- Support seal ring retainer. with the sleeve. of the special tool.
I
Assembly tool (Tl50S)
(or
p. 266)
- Press the special tool through the new pilot bushing.
I
Calibration pin (Tl205) (or p. 263)
, / The pilot bushing is to be calibrated.
- Assemble the seal ring retainer. (or p. 52)
Condition
The damper has been disassembled.
- Measure the inside diameter on both ends and in the middle of the damper car-
tridge.
Damper tube
Diameter 50.08 mm (1.9716 in)
• If the measured value is greater than the specified value:
- Replace the damper cartridge.
- Check the damper cartridge for damage and wear.
• If there is damage or wear:
- Replace the damper cartridge.
- Check the heim joint for damage and wear.
• If there is damage or wear:
- Replace the heim joint.
48
04LSHOCK ABSORBER, SWINGARM
Replacinllhe pilot bushinl
200798-10
Checkinllhe damper
200811-10
- Disassemble the seal ring retainer. (or p. 47)
- Press pilot bushing. out of seal ring retainer. using the special tool.
I
Press drift (Tl504)
(or
p. 266)
- Slide the new pilot bushing. onto the special tool.
I
Press drift (Tl504) (or p. 266)
- Position the pilot bushing in the seal ring retainer using the special tool.
I
Press drift (Tl504)
(or
p. 266)
- Support seal ring retainer. with the sleeve. of the special tool. Press the pilot
bushing all the way in.
I
Assembly tool (Tl50S)
(or
p. 266)
- Lubricate the special tool.
Shock absorber oil (SAE 2,5) (50180342S1)
(or
p. 250)
Calibration pin (Tl205) (or p. 263)
- Support seal ring retainer. with the sleeve. of the special tool.
I
Assembly tool (Tl50S)
(or
p. 266)
- Press the special tool through the new pilot bushing.
I
Calibration pin (Tl205) (or p. 263)
, / The pilot bushing is to be calibrated.
- Assemble the seal ring retainer. (or p. 52)
Condition
The damper has been disassembled.
- Measure the inside diameter on both ends and in the middle of the damper car-
tridge.
Damper tube
Diameter 50.08 mm (1.9716 in)
• If the measured value is greater than the specified value:
- Replace the damper cartridge.
- Check the damper cartridge for damage and wear.
• If there is damage or wear:
- Replace the damper cartridge.
- Check the heim joint for damage and wear.
• If there is damage or wear:
- Replace the heim joint.
48