Tolerance And Fitting Clearances - KTM 2003 950 Adventure Repair Manual

11-17
TOLERANCES AND FITTING CLEARANCES
COMPONENT
Valves
Valve springs 950
Valve springs 990
Camshafts/cylinder head
950
Camshafts/cylinder head
990
Cylinder 950
Cylinder 990
Piston 950
Piston 990
Piston ring 950
Piston ring 990
Piston pin / piston
MEASUREMENT/TEST . . . . . . . . . . . . . . . . . . . . . . .SETPOINT VALUE .TOLERANCE LIMIT
Valve clearance (at 20ºC) intake . . . . . . . . . . . . . . . .0,10 mm - 0,15 mm
Valve clearance (at 20ºC) exhaust . . . . . . . . . . . . . . .0,25 mm - 0,30 mm
Valve shaft runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.1mm
Sealing seat width, intake . . . . . . . . . . . . . . . . . . . . .1.2 mm – 1.8 mm
Sealing seat width, exhaust . . . . . . . . . . . . . . . . . . . .1.5 mm – 2.0 mm
Valve disk runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.03 mm
Valve guide, inner diameter . . . . . . . . . . . . . . . . . .6.006 mm – 6.018 mm . . .max. 6.05 mm
Valve shaft, outer diameter, intake . . . . . . . . . . . . .5.967 mm – 5.980 mm
Valve shaft, outer diameter, exhaust . . . . . . . . . . . .5.973 mm – 5.987 mm
Inner length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 39.4 mm . . . . . .min. 38.0 mm
Outer length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 42.8 mm . . . . . .min. 41.3 mm
Inner length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . .new 37.8 mm . . . . . . .min.37.0 mm
Outer length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . new 42.0 mm . . . . . . .min.41.2 mm
Cam height, intake . . . . . . . . . . . . . . . . . . . . . . . .37.80 mm – 37.90 mm
Cam height, exhaust . . . . . . . . . . . . . . . . . . . . . . .36.45 mm – 36.55 mm
Cam height, intake . . . . . . . . . . . . . . . . . . . . . . . .38.75 mm - 38.85 mm
Cam height, exhaust . . . . . . . . . . . . . . . . . . . . . . .38.15 mm - 38.25 mm
Camshaft bearing bore . . . . . . . . . . . . . . . . . . . .24.000 mm – 24.021 mm
Camshaft bearing journal . . . . . . . . . . . . . . . . . . .23.960 mm 23.980 mm
Camshaft bearing clearance . . . . . . . . . . . . . . . . . .0.020 mm – 0.061 mm . . .max. 0.09 mm
Cylinder head distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100.000 mm – 100.012 mm
Size II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100.013 mm – 100.025 mm
Cylinder distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.000 mm – 101.012 mm
Size II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.012 mm – 101.025 mm
Cylinder distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
Size I – 9 mm (from lower edge) . . . . . . . . . . . . .99.953 mm – 99.967 mm
Size II – 9 mm (from lower edge) . . . . . . . . . . . . .99.963 mm – 99.977 mm . . . .99.930 mm
Mounting clearance . . . . . . . . . . . . . . . . . . . . . . . .0.04 mm – 0.06 mm . . . . . . . .0.10 mm
Size I – 9 mm (from lower edge) . . . . . . . . . . . .100.943 mm – 100.957 mm
Size II – 9 mm (from lower edge) . . . . . . . . . . . .100.953 mm – 100.967 mm . .100.930 mm
Mounting clearance . . . . . . . . . . . . . . . . . . . . . . . .0.05 mm – 0.07 mm . . . . . . . .0.10 mm
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 mm – 0.35 mm . . . . . . . . .0.5 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .0.92 mm – 0.94 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .1.80 mm – 1.84 mm . . . . . . . . . . . . . .
Width of piston ring groove – 2nd ring . . . . . . . . . . .1.27 mm – 1.29 mm . . . . . . . . . . . . . .
Width of piston ring groove – oil scraper ring . . . . . . .2.51 mm – 2.53 mm . . . . . . . . . . . . . .
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .0.85 mm – 0.87 mm . . . . . . . . . . . . . .
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .1.20 mm – 1.22 mm . . . . . . . . . . . . . .
Thickness of 2nd ring . . . . . . . . . . . . . . . . . . . . . . .1.22 mm – 1.24 mm . . . . . . . . . . . . . .
Thickness of oil scraper ring . . . . . . . . . . . . . . . . . .2.47 mm – 2.49 mm
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 mm – 0.35 mm . . . . . . . . .0.5 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .0.92 mm – 0.94 mm
Width of piston ring groove – 1st ring (L-ring) . . . . . .1.80 mm – 1.84 mm
Width of piston ring groove – 2nd ring . . . . . . . . . . .1.25 mm – 1.29 mm
Width of piston ring groove – oil scraper ring . . . . . . .2.50 mm – 2.53 mm
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .0.85 mm – 0.88 mm
Thickness of 1st ring (L-ring) . . . . . . . . . . . . . . . . . .1.20 mm – 1.27 mm
Thickness of 2nd ring . . . . . . . . . . . . . . . . . . . . . . .1.22 mm – 1.24 mm
Thickness of oil scraper ring . . . . . . . . . . . . . . . . . .2.47 mm – 2.49 mm
Diameter of piston ring bore . . . . . . . . . . . . . . . .22.006 mm – 22.011 mm . . . .22.030 mm
Diameter of piston pin . . . . . . . . . . . . . . . . . . . .21.996 mm – 22.000 mm . . . .21.980 mm