Cylinder Head Rear With Timing Chain - KTM 2003 950 Adventure Repair Manual

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4
1
2
5
3
5

Cylinder head rear with timing chain

– Remove the M10x161 stud bolts, strength class 10.9, and replace
with stud bolts in class 12.9.
NOTE: you can tell the two strength classes apart by their thread
length. Stud bolts in class 12.9 have a thread length of 26 mm; stud
bolts in any other length must be replaced.
– Mount a new base gasket.
NOTE: make sure the crankshaft is blocked in the cylinder rear TDC
position.
– Fit the timing chain and chain tensioning rail in the cylinder.
NOTE:
– The chain guide is mounted on the exhaust side of cylinder rear.
– The timing chain should be drawn up and held in the chain tunnel
with a thin welding wire
1
– Push the cylinder head and cylinder over the stud bolts until the
piston pin can be pressed into the piston by hand from the output
end. Insert a new piston pin retainer with a screwdriver into the
piston groove.
!
– D
O NOT PULL THE PISTON OUT OF THE CYLINDER UP TO THE OIL SCRAPER RING
SINCE THE PISTON RING WILL BE DAMAGED BY THE LOWER EDGE OF THE
.
CYLINDER
– T
HE OPENING TOWARDS THE CRANKSHAFT SHOULD BE COVERED WITH A CLOTH
TO PREVENT THE PISTON PIN RETAINER FROM FALLING OUT OF THE ENGINE
.
CASE
– T
HE PISTON PIN RETAINER
.
ILLUSTRATION
Push the cylinder head and cylinder down. Oil the cylinder head
nuts and mount with the washer - see Technical Information.
The cylinder head nuts are tightened in 2 stages.
1st stage:
– Tighten the cylinder head nuts crosswise. Use the special nut
600.29.083.000 for the internal nuts
600.29.081.000 for the outer nut
!
– T
HE TIGHTENING TORQUE FOR THE
600.29.081.000
WRENCH
23 N .
M
– T
HE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (
SEE ILLUSTRATION
– Tighten the two outer nuts
2nd stage:
– Tighten the cylinder head nuts crosswise.
!
– T
HE TIGHTENING TORQUE FOR THE
600.29.081.000
WRENCH
34 N .
M
– T
HE TORQUE WRENCH USED MUST BE USED IN LINE WITH THE SPECIAL WRENCH
600.29.081.000 (
SEE ILLUSTRATION
or a rubber band.
CAUTION
2
MUST BE IN THE POSITION SHOWN IN THE
and the special wrench
3
.
4
CAUTION
1 25 N .
ST STAGE IS M SINCE THE SPECIAL
,
4
IS USED FOR NUT IT MUST BE TIGHTENED TO
).
to 8 Nm.
5
CAUTION
2 38 N .
ND STAGE IS M SINCE THE SPECIAL
,
4
IS USED FOR NUT IT MUST BE TIGHTENED TO
).
!
!
!