KTM 450 SX-F Repair Manual page 45

SERVICING INDIVIDUAL COMPONENTS
LEFT ENGINE CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
RIGHT ENGINE CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
BALANCER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
AXIAL CLEARANCE OF THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
PISTON / CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
AUTOMATIC DECOMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
RADIAL CLEARANCE OF THE CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . .5-12
CAMSHAFT BEARING BRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
TIMING TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
GENERAL INFORMATION ON SERVICING THE TRANSMISSION . . . . . . . . . . . . . .5-21
MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
IGNITION COVER / STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
Read through the following section before commencing work. Then determine the assembly sequence so that the engine housing halves only
need to be heated up once before replacing the bearings.
Having first removed the dowels, needle roller and rollers, in order to expel the bearings or remove them with light mallet blows, the housing
halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is
best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and hammer
them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx. 150°C .
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must be replaced.
INDEX
IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING
5-1
5