Replacing The Conrod Bearings; Selecting The Bearing Shells - KTM 990 Adventure Repair Manual

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Replacing the conrod bearings

– Clamp each conrod in a vise using protective jaws.
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– Loosen the bolts
NOTE: mark the conrod caps to ensure that each cap is mounted to the
same conrod when it is measured and assembled.
– Remove the conrod caps.
– Clean the crankshaft and blow compressed air through the

Selecting the bearing shells

Before you select the new bearing shells you must measure the conrod
journal.
– Measure the diameter of the conrod journal at 3 points that are
Diameter of the conrod journal:
NOTE:
– Use the bearing color indicated for the respective measurement.
– The crankshaft must be replaced if the measurement falls short of
– Clamp each conrod in a vise, insert new bearing shells, position the
–
–
– Unclamp the conrods and compare the width of the plastigauge
Setpoint value of the conrod bearing clearance:
– Clamp each conrod in a vise using protective jaws, apply a thin layer
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T
CONROD TO ALLOW ROOM FOR THE CRANKSHAFT RADIUS
MOUNTED BACKWARDS
RADIUS AND BLOCK THE CONRODS
– Tighten the conrod bearing bolts with the special wrench socket
NOTE: use a degree wheel
conrod bearing bolts are tightened correctly.
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on the conrod bearing covers with the special
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wrench socket 600.29.075.000 and remove the bearing covers.
lubrication bores.
120° apart using a micrometer gauge.
the minimum diameter or if the crankshaft is worn.
crankshaft with a plastigauge measuring strip
on top and mount the conrod caps with the old bolts, as described
below.
!
INSERT THE PLASTIGAUGE MEASURING STRIPS AT A
.
END GAP
DO NOT TURN THE CONRODS ON THE CONROD JOURNAL
measuring strip with the information on the packing. The width of
the plastiguage measuring strip is equivalent to the bearing
clearance.
0.030 mm – 0.060 mm
Wear limit: 0.080 mm
of Molycote grease to the bearing shells, position the crankshaft and
mount the conrod caps with new bolts.
!
HE BEARING SHELLS SHOULD BE MOUNTED IN AN OFFSET POSITION IN THE
,
THE BEARING SHELLS WILL EXERT PRESSURE ON THE
600.29.075.000 to 25 Nm (1st stage). The tighten to 30 Nm (2nd
stage) and finally by another 60° (3rd stage).
41.978 mm – 41.989 mm (yellow)
41.990 mm – 42.000 mm (blue)
42.001 mm – 42.011 mm (red)
(600.29.012.000)
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CAUTION
90°
ANGLE TO THE BEARING
.
CAUTION
.
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IF THE CONRODS ARE
.
(600.29.010.000) to make sure the
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!
!