Piston And Cylinder Identification; Assembling The Cylinder Head - KTM 2003 950 Adventure Repair Manual

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2
7
6
5
4
3

Piston and cylinder identification

The cylinder size
chain tunnel; 1 is size I, 2 is size II.
1
The piston size
size II.

Assembling the cylinder head

– Slide the valve spring washers
new valve shaft seals
– Lubricate the valve shafts and insert the valves in their original
position in the valve guides.
NOTE:
– A washer to increase the spring preload is located under the spring
retainers.
– A washer with a thickness of 1 mm was installed up to engine
number 2-600-00070.
– Two washers with a thickness of 1 mm were installed in the engines
with the engine number 2-600-00071 to 2-600-00124
– A washer with a thickness of 2 mm (14x30x2) was installed in
engine number 2-600-00125. It can also be used for earlier
engines.
– Mount the inner and outer valve springs
and compress the springs using the valve assembling tool
6
(590.29.019.000 with the attachment 600.29.041.000).
– Grease the valve spring keys
Relieve the valve springs.
– Tap the valve spring retainers to set the keys.
is impressed in the bottom of the cylinder near the
1
is impressed in the top of the piston; 1 is size I, 2 is
2
over the valve guides and mount
3
.
4
and position on the valve shafts.
7
with the spring retainers
5