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

6-17
75º
Setting cylinder front to TDC
– Loosen
counterclockwise 1 rotation and then 75° towards the front
cylinder's TDC position, keeping the timing chain on the cylinder
rear slightly tensioned and holding the conrod in the center of the
opening in the case.
– T
HE
COUNTERCLOCKWISE DIRECTION
BE CORRECT AND THE MOTOR WILL NOT RUN
– I
F YOU DO NOT HOLD THE CHAIN
CHAIN ON THE CRANKSHAFT AND THE TENSIONING RAIL
– I
F THE CONROD IS NOT POSITIONED IN THE CENTER OF THE OPENING IN THE
CASE
PREVENT THE CRANKSHAFT FROM TURNING
– Screw the crankshaft locking bolt back in.

Cylinder head front with cylinder and timing chain

– Remove the M10x161 stud bolts, strength class 10.9, and replace
with stud bolts in class 12.9.
1
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 front TDC
position.
– Fit the timing chain and chain tensioning rail in the cylinder. Tilt the
chain tensioning rail
the chain tunnel of the engine case.
NOTE:
– The chain guide is mounted on the intake side of cylinder front .
– The timing chain should be drawn up and held in the chain tunnel
with a thin welding wire or a rubber band.
– 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
2
the crankshaft locking
! CAUTION
CRANKSHAFT MUST BE TURNED
,
OTHERWISE THE IGNITION INTERVAL WILL NOT
,
IT MAY GET JAMMED BETWEEN THE TIMING
,
THE CONROD BOTTOM WILL BLOCK ON THE BALANCER SHAFT AND
towards the chain to allow it to engage in
1
! CAUTION
.
.
2
MUST BE IN THE POSITION SHOWN IN THE
.
bolt and turn the engine
!
1 75°
ROTATION AND IN
.
.
.
!
A