Checking Piston Ring End Gap; Checking Piston/Cylinder Mounting Clearance; Checking Oil Pumps For Wear - KTM 690 Enduro R EU 2012 Repair Manual

17 ENGINE

17.4.14 Checking piston ring end gap

17.4.15 Checking piston/cylinder mounting clearance

–
Check/measure the cylinder. (
–
Check/measure the piston. (
–
The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam-
eter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston
diameter.
Guideline
Piston/cylinder - mounting clearance
New condition
Wear limit

17.4.16 Checking oil pumps for wear

Info
The oil pump wear check shown here is on the suction pump but it applies to all oil pumps.
–
Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance
B
Guideline
Distance
Piston - diameter
Size I
Size II
302138-10
Info
Piston size
–
Remove the piston ring from the piston.
–
Place the piston ring in the cylinder and align it with the piston.
Guideline
Under the upper edge of the cylinder
–
Measure the end gap with a feeler gauge
Guideline
Piston ring end gap
Compression rings
300098-10
Oil scraper ring
» If the end gap is more than the specified value:
–
Check/measure the cylinder. (
» If the cylinder wear is within the tolerance range:
–
Change the piston ring.
–
Mount the piston ring with the marking facing toward the piston head.
p. 129)
p. 130)
–
Use a feeler gauge
engine case as well as between the external rotor and the internal rotor.
Oil pump
Clearance between external rotor
and engine case
Clearance between external rotor
and internal rotor
Axial clearance
300106-10
.
B
is marked on the piston head.
1
0.035... 0.060 mm (0.00138... 0.00236 in)
0.10 mm (0.0039 in)
to measure the play between the external rotor and the
1
31.5 mm (1.24 in)
101.955... 101.965 mm (4.01397...
4.01436 in)
101.965... 101.975 mm (4.01436...
4.01476 in)
10 mm (0.39 in)
.
A
≤ 0.80 mm (≤ 0.0315 in)
≤ 1.00 mm (≤ 0.0394 in)
p. 129)
≤ 0.20 mm (≤ 0.0079 in)
≤ 0.20 mm (≤ 0.0079 in)
0.04... 0.08 mm (0.0016...
0.0031 in)
131