Automatic Tensioner; Preassembly Of Automatic Tensioner; Disassembling The Oil Pumps And Checking The Components For Wear - KTM 400-660 LC4 1998-2005 Repair Manual

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Automatic tensioner

– Check ratcheting pawl
– Check thrust bolt

Preassembly of automatic tensioner

– Insert thrust bolt into tensioner housing and engage ratcheting pawl
into first notch (see illustration).
!
I
F THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE
EXCESSIVE TENSION OF THE CHAIN
Disassembling the oil pumps and checking the components
for wear
NOTE: The two oil pumps are similar in design but work at different
speeds. Disassemble and check the oil pumps separately to avoid mixing
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up of components.
– Remove screw
– Pull the oil pump shaft
the bearing needle.
– Take the inner rotor
housing.
– Clean all components and check for signs of wear.
– When reassembling the unit insert the inner rotor and the outer rotor
into the oil pump housing, making sure that the point faces the
inside.
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– Mount oil pump shaft and bearing needle
– Now perform the following measurements to determine the degree
of wear:
Outer rotor - oil pump housing: max. 0.20 mm
– Fill the oil pump housing with oil and mount the oil pump cover.
– Apply Loctite 243 to the thread of screw
!
F
ILL OIL PUMPS WITH OIL BEFORE PREASSEMBLING
1
for smooth operation and wear.
2
for wear at teeth.
CAUTION
.
3 and take off the oil pump cover
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out of the oil pump housing together with
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and the outer rotor
Outer rotor - inner rotor: max. 0.20 mm
CAUTION
.
5-13E
!
4 .
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out of the oil pump
3
and mount the screw.
!