Double Timing Gear; Cylinder Head Rear With Cylinder; Setting Cylinder Front To Tdc - KTM 990 Adventure Repair Manual

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3
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Double timing gear

– Lift the double timing gear out of the cylinder head, letting the
chain fall into the slot.

Cylinder head rear with cylinder

– Remove the outer nut .
1
– Loosen the cylinder-head
600.29.083.000 is required for the inside nuts
– Pull the cylinder head and cylinder up until the piston-pin retainer
can be lifted out of the groove on the generator side with a suitable
screwdriver.
NOTE: the piston-pin retainer can easily be removed if the piston is
held in place by the cylinder.
– Press the piston pins out of the piston by hand and remove the
cylinder together with the piston.
– Discard the cylinder-base gasket.

Setting cylinder front to TDC

Loosen the crankshaft locking bolt and continue to turn the engine
towards the front cylinder's TDC position, keeping the timing chain on
the rear cylinder slightly tensioned and holding the conrod in the
center of the opening in the case.
!
– I
F YOU DO NOT HOLD THE CHAIN
GEAR OF THE BALANCER SHAFT AND THE TENSIONING RAIL
– I
F THE CONROD IS NOT POSITIONED IN THE CENTER OF THE OPENING IN THE
,
CASE THE CONROD BOTTOM WILL BLOCK ON THE BALANCER SHAFT AND
PREVENT THE CRANKSHAFT FROM TURNING
– Turn the crankshaft until the front cylinder is in the TDC position.
The marks (circles) must coincide with the flat outer surface of
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the cylinder head at the camshaft gears.
– The same camshaft gears are used in both cylinders but they have
marks for cylinder rear and front. Use the camshaft gear marked
with a cross for cylinder rear and the camshaft gear marked with a
circle for cylinder front cylinder.
– Block the crankshaft again.
nuts crosswise.
.
2
CAUTION !
,
IT MAY GET JAMMED BETWEEN THE TIMING
.
.
Special nut