Work On Individual Components; Left Housing Half; Right Housing Half - KTM S5-E Repair Manual

4.0 WORK TO BE PERFORMED ON INDIVIDUAL COMPONENTS
E
NGINE HOUSING
N : R
OTE EAD THROUGH THE FOLLOWING SECTION BEFORE COMMENCING WORK
THE HOUSING HALVES NEED NOT BE HEATED MORE THAN ONCE TO INSERT THE BEARINGS
B -
EFORE PRESSING OR IF NECESSARY
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THE DOWEL PINS O PREVENT DAMAGING OF THE SEALING SURFACE
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SUPPORTING SURFACE E RECOMMEND TO PLACE THE HOUSING HALVES ON A WOODEN BOARD
A
MANDREL SHOULD NOT BE USED TO INSERT BEARINGS OR SHAFT SEAL RINGS
USED VERY CAREFULLY TO INSERT BEARINGS OR SHAFT SEAL RINGS
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THEIR SEATS QUITE EASILY ANYHOW
I
F THE BEARINGS ARE NOT LOCKED TIGHT IN THEIR SEATS AFTER COOLING
. I ,
HEATS UP N THIS CASE THE HOUSING MUST BE REPLACED
2
3
5
- ,
HAMMERING OUT THE BEARINGS
,
ENSURE THAT THE ENTIRE SEALING SURFACE OF THE HOUSING IS PROPERLY RESTING ON THE
. A
T A HOUSING TEMPERATURE OF APPROXIMATELY
REQUIRING ALMOST NO ADDITIONAL ATTENTION
.

4.1 Left housing half

Remove the shaft seal rings and heat the housing half, using a hot plate, to a tem-
perature of approximately 150° C.
G
Use a suitable mandrel to press the grooved ball bearing inwards.
Insert a new grooved ball bearing from inside, pressing it all the way into the recess.
G
Use a suitable mandrel to press the grooved ball bearing inwards.
Insert a new grooved ball bearing from inside, pressing it all the way into the recess.
1
A
SO AS TO PREVENT DAMAGING OF THE HOUSING
S
HAFT SEAL RING OF THE CRANKSHAFT
Insert a new shaft seal ring from outside, the sealing lip facing inwards. The seal ring
must be 2 mm (0.08 in.) below the edge of the housing.
S
HAFT SEAL RING OF THE COUNTERSHAFT
Insert a new shaft seal ring from outside, the sealing lip facing inwards. The seal ring
must be flush with the edge of the housing.
4

4.2 Right housing half

Remove the shaft seal ring and heat the housing half, using a hot plate, to a tempe-
rature of approximately 150° C.
G
Use a suitable mandrel to press the grooved ball bearing inwards.
Insert a new grooved ball bearing from inside, pressing it all the way into the recess.
G
Use a suitable mandrel to press the grooved ball bearing inwards.
Insert a new grooved ball bearing from inside, pressing it all the way into the recess.
6
A
SO AS TO PREVENT DAMAGING OF THE HOUSING
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HEN DETERMINE IN WHICH ORDER THE PARTS MUST BE MOUNTED TO ENSURE THAT
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PLACE THE HOUSING HALVES ON A SUFFICIENTLY LARGE PLANE SURFACE
.
. H ,
OWEVER IF A SUITABLE PRESSING DEVICE IS NOT AVAILABLE
.
,
THEY MUST BE EXPECTED TO CHANGE THEIR POSITION WITHIN THE HOUSING AS THE UNIT
ROOVED BALL BEARING OF THE CRANKSHAFT
ROOVED BALL BEARING OF THE COUNTERSHAFT
!
CAUTION
PPLY ONLY SLIGHT PRESSURE WHEN INSERTING GROOVED BALL BEARING INTO THE HOUSING
ROOVED BALL BEARING OF THE CRANKSHAFT
ROOVED BALL BEARING OF THE COUNTERSHAFT
!
CAUTION
PPLY ONLY SLIGHT PRESSURE WHEN INSERTING GROOVED BALL BEARING INTO THE HOUSING
(
AFTER REMOVING
,
A MANDREL CAN BE
150° C,
THE COLD BEARINGS WILL SLIDE INTO
1
2
!
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3
4
5
6
!
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