30/Engine - Work On Individual Parts; Work On The Right Section Of The Engine Case - KTM 690 Enduro EU 2009 Repair Manual

30/ENGINE - WORK ON INDIVIDUAL PARTS

Work on the right section of the engine case

19.1
–
Remove oil jet
–
Remove bearing locks of the main shaft bearing
and of the shift drum bearing
–
Remove any sealing mass remnants and clean the engine case section thoroughly.
–
Pull the dowels out of the housing.
–
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
300094-10
–
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.
–
Remove oil jet
–
Remove the cover plate
–
Press out the shaft seal ring
–
Remove the shaft seal rings
–
Press in the shaft seal ring
the open side facing in.
Info
The shaft seal ring must be flush on the outside.
300095-10
–
Press in the shaft seal rings of the water pump with the open side facing out so
that it is flush.
–
Warm the engine case section again.
Guideline
150 °C (302 °F)
–
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 from the inside to
the outside, all the way to the stop or so it is flush.
Info
The shift shaft bearing
until it is flush.
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
300096-10
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.
–
Position all bearing locks. Mount and tighten the screws.
Guideline
Locking screw for bearing
–
Mount and tighten the oil jet
Guideline
Oil jet, piston cooling
–
Mount and tighten the oil jet
.

.

.

for the oil return line.

of the crankshaft from the inside to the outside.

of the water pump.

of the crankshaft from the outside to the inside with

must be pressed in from the outside to the inside

M5
.

M6x0.75
.

, of the countershaft bearing

6 Nm Loctite ® 243™
(4.4 lbf ft)
4 Nm Loctite ® 243™
(3 lbf ft)
122
,
