Replacing The Main Bearings-General Information - KTM 2003 950 Adventure Repair Manual

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Replacing the main bearings-general information

NOTE:
– The bearing shells for the friction bearings are pressed in and out in
a cold state.
– Mark the position of the bearing end gap
a felt-tip pin to facilitate reassembly.
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NOTE: the main bearing shells have retaining brackets to hold them in
position from the 2005 model; they must be removed before the main
bearing shells are pressed out and mounted again after the main
bearing shells are remounted; apply Loctite 243 to the screws and
tighten to 6 Nm.
– Press the main bearing shells out of both engine case halves from
the inside to the outside using the press mandrel 600.29.044.050
(smaller diameter).
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Before you select the bearing shells you must measure the crankshaft.
– Measure the diameter of the two main bearing pins at 3 points that
are 120° apart using a micrometer gauge. This only applies to
crankshafts that you will continue to use.
Diameter of main bearing pin: 49.965 mm – 49.975 mm (yellow)
NOTE:
– Use the bearing color indicated for the respective measurement.
– The crankshaft must be replaced if the measurement falls short of
the minimum diameter or if the crankshaft is worn.
– New crankshafts do not need to be measured. Use new bearings
according to the colored circles
the new crankshaft.
NOTE:
– there are 2 types of bearings for each bearing color – the grooved
bearing shell (with the lubricating groove and oil bore) is pressed
into the top of the case half of the generator end and the smooth
bearing shells (without lubricating groove) are pressed into the
bottom of the case half of the generator end and into the case half
of the output end - applicable for models up to the 2004 model.
– Bearing shells with grooves on the top and bottom (with lubricating
groove and lubrication bore) are mounted on the generator end of
the housing half from the 2005 model.
– A new crankshaft comes with 2 grooved bearing shells. They can
also be installed in engines preceding the 2004 model.
!
I
F YOU MOUNT A BEARING SHELL THAT IS SMOOTH ON THE BOTTOM ON THE
GENERATOR END OF THE ENGINE FROM THE
COOL THE PISTON WILL NOT BE SUPPLIED WITH LUBRICATING OIL AND WILL LEAD TO
.
DAMAGE
– Measure the bearing bores with a micrometer to ensure that the
bearing shells are seated firmly in the engine case after being
pressed in.
Nominal dimension: 54.000 mm – 54.015 mm
NOTE: if the bearing bores are too big, the engine case must be
replaced.
Measure the inner diameter of the bearings after they are pressed in to
ensure that the bearing clearance is correct.
NOTE: the inner diameter of the bearings must be measured at a 90°
angle to the bearing end gap.
The diameter of the main bearing pin must be deducted from the inner
diameters of the bearings, the difference is the radial clearance of the
main bearing.
Setpoint value for the radial clearance of the main bearing:
Example: Inner bearing diameter measured 50.020 mm
Main bearing pin measured 49.980 mm
50.020 – 49.980 = 0.040 mm radial clearance
on the engine case with
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49.976 mm – 49.985 mm (blue)
49.986 mm – 49.995 mm (red)
marked on the crankshaft web of
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CAUTION
2005
MODEL
0.025 mm – 0.055 mm
Wear limit: 0.080 mm
!
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