Replacing Bearing Shells, Output End; Replacing Bearing Shells, Generator End - KTM 2003 950 Adventure Repair Manual

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Replacing bearing shells, output end

– Center the new bearing shells (both smooth) with the assembling
sleeve 600.29.044.050
one side so the bearing shells can be pushed in easily. The bearing
shells should protrude 1-2 mm on the other side of the assembling
sleeve to make it easier to position them in the engine case.
– Position the bearing shells on the output end of the case such that
the end gap on the bearing shells points to the marks
disassembling.
– Press in the bearings from the outside to the inside through the
assembling sleeve up to the stop using the press mandrel
600.29.044.050
3
–
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE
OTHERWISE THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII
OF THE CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS
WHY THE BEARING SHELLS ARE SEATED
BEARING BORE
–
THE ASSEMBLING SLEEVE SERVES AS A STOP
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION

Replacing bearing shells, generator end

– Center the new bearing shells (smooth on the bottom, grooved on
top up to the 2004 model, both grooved from the 2005 model) with
the assembling sleeve 600.29.044.050 – same procedure as for the
bearing shells, output end (see above).
– Position the bearing sleeves at the generator end of the case with
the bearing shell end gap pointing to the marks
disassembling. Do not cover the oil bore.
– Press the bearings into the engine case half from the outside to the
inside through the assembling sleeve up to the stop using the
special tool 600.29.044.050.
–
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE OTHERWISE
THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII OF THE
CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS
BEARING SHELLS ARE SEATED
–
THE ASSEMBLING SLEEVE SERVES AS A STOP
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION
–
IF THE BEARING SHELLS ARE INCORRECTLY ALIGNED OR IF SMOOTH BEARING
SHELLS ARE PRESSED IN ON TOP
TO
INTERRUPTED
– I
F A SMOOTH BEARING SHELL IS INSTALLED ON THE GENERATOR END IN ENGINES
STARTING WITH THE
NOT BE SUPPLIED WITH LUBRICATING OIL AND WILL LEAD TO DAMAGE
NOTE:
– After replacing all friction and roller bearings, dismount the spraying
nozzles and oil nozzles and clean the oil ducts with compressed air
to make sure they are not clogged.
– Coat the friction bearings with Molycote grease.
Apply Loctite 243 to the spraying nozzles and oil nozzles and tighten to 6 Nm.
. The assembling sleeve is beveled on
1
.
3
! CAUTION
.
! CAUTION
2
MM BELOW THE EDGE OF THE BEARING BORE
,
THE OIL SUPPLY TO THE SPRAYING NOZZLES
COOL THE PISTONS AND LUBRICATE
,
LEADING TO SERIOUS ENGINE DAMAGE
2005 ,
MODEL THE WATER JET TO COOL THE PISTONS WILL
5-4
made when
2
!
.
THIS IS
2
MM BELOW THE EDGE OF THE
.
IT IS NOT REMOVED UNTIL THE
.
made when
4
!
.
THIS IS WHY THE
.
.
IT IS NOT REMOVED UNTIL THE
.
THE TIMING CHAIN WILL
.
.
BE