KTM 1190 RC8 R EU/UK 2009 Repair Manual page 6

CONTENTS
Preparing the timing chain tensioner for installation ....... 154
Checking the oil pressure regulator valve........................ 155
Checking the oil pumps................................................ 155
Checking the clutch..................................................... 156
Checking the shift mechanism ...................................... 157
Preassembling the shift shaft........................................ 158
Dismantling the main shaft .......................................... 158
Dismantling the countershaft........................................ 159
Checking the transmission............................................ 160
Assembling the main shaft ........................................... 161
Assembling the countershaft......................................... 161
30/ASSEMBLING THE ENGINE ........................................ 163
Installing the timing chain rails of the left engine case
section ....................................................................... 163
Installing the timing chain rails of the right engine case
section ....................................................................... 163
Installing the oil spray tube .......................................... 164
Installing the transmission shaft ................................... 164
Installing the middle suction pump ............................... 165
Installing the crankshaft............................................... 165
Installing the left engine case ....................................... 166
Installing the locking lever............................................ 167
Installing the shift drum locating .................................. 167
Installing the shift shaft ............................................... 167
Installing the force pump ............................................. 168
Installing the left suction pump .................................... 169
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 169
Installing the primary gear............................................ 170
Installing the outer clutch hub...................................... 170
Installing the clutch facing........................................... 171
Installing the idler and timing chain on the right ............ 172
Installing the clutch cover ............................................ 172
Installing the water pump wheel ................................... 173
Installing the gear position sensor ................................. 173
Installing the drive wheel of the balancer shaft............... 173
Installing the balancer shaft ......................................... 174
Installing the idler and timing chain on the left .............. 174
Installing the oil filter .................................................. 175
Installing the rotor ....................................................... 175
Installing the torque limiter and idler ............................ 176
Installing the ignition pulse generator............................ 176
Installing the generator cover........................................ 176
Installing the oil drain plug........................................... 176
Installing the rear piston .............................................. 177
Installing the rear cylinder head.................................... 178
Installing the rear camshaft .......................................... 179
Installing the rear timing chain tensioner ....................... 179
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 180
Installing the front piston ............................................. 180
Installing the front cylinder head................................... 182
Installing the front camshafts ....................................... 182
Installing the front timing chain tensioner...................... 183
Installing the heat exchanger ........................................ 183
Installing the oil filler tube ........................................... 184
Installing the starter motor ........................................... 184
Checking the rear cylinder control time.......................... 184
Adjusting the rear cylinder control time ......................... 184
Checking the rear valve clearance ................................. 185
Adjusting the rear valve clearance ................................. 186
Checking the front cylinder control time ........................ 186
Adjusting the front cylinder control time ........................ 186
Checking the front valve clearance ................................ 187
Adjusting the front valve clearance................................ 188
Installing the front valve cover ...................................... 188
Installing the rear valve cover ....................................... 188
Mounting the engine bracket ........................................ 189
Dismounting the engine from the work stand.................. 189
31/SECONDARY AIR SYSTEM .......................................... 190
Exhaust air injection .................................................... 190
32/CLUTCH .................................................................... 191
Checking fluid level of hydraulic clutch ......................... 191
Correcting fluid level of hydraulic clutch ........................ 191
34/SHIFT MECHANISM ................................................... 192
Adjusting shift lever stub.............................................. 192
Adjusting shift lever..................................................... 192
35/WATER PUMP, COOLING SYSTEM .............................. 194
Checking the coolant level............................................ 194
Checking the antifreeze................................................ 194
Removing the radiator .................................................. 195
Installing the radiator................................................... 195
Adding coolant/bleeding the cooling system ................... 196
Filling the cooling system compensating tank................. 197
36/CYLINDER HEAD........................................................ 198
Engine coolant temperature sensor cylinder 1 ................ 198
Engine coolant temperature sensor for cylinder 2............ 199
Checking the valve clearance ........................................ 200
Adjusting the rear valve clearance ................................. 201
Adjusting the front valve clearance................................ 202
Checking the rear cylinder control time.......................... 202
Checking the front cylinder control time ........................ 202
Adjusting the rear cylinder control time ......................... 203
Adjusting the front cylinder control time ........................ 204
Removing the rear camshaft ......................................... 205
Installing the rear camshaft .......................................... 205
Removing the front camshafts ...................................... 206
Installing the front camshafts ....................................... 206
Installing the rear timing chain tensioner ....................... 207
Installing the front timing chain tensioner...................... 207
38/LUBRICATION SYSTEM .............................................. 208
Oil circuit ................................................................... 208
Checking the engine oil level ........................................ 209
Changing the engine oil and filter, cleaning the oil
screens....................................................................... 209
Draining engine oil, cleaning oil screens ........................ 209
Removing the oil filter.................................................. 211
Installing the oil filter .................................................. 212
Filling up with engine oil.............................................. 212
Adding engine oil ........................................................ 213
Checking the engine oil pressure................................... 213
Removing the oil jet for the clutch lubrication ................ 215
Checking / cleaning the oil jet for clutch lubrication........ 216
Installing the oil jet for the clutch lubrication................. 216
39/IGNITION SYSTEM ..................................................... 218
Crankshaft position sensor............................................ 218
Ignition coil ................................................................ 218
41/THROTTLE VALVE BODY............................................. 219
Throttle position sensor circuit A................................... 219
Throttle position sensor circuit A - checking in the
"zero" position ............................................................. 219
Adjusting the position of the throttle position sensor in
circuit A ..................................................................... 220
Removing the throttle valve body to adjust ..................... 221
4