Replacing Bearing Shells, Output End; Replacing Bearing Shells, Generator End - KTM 950 ADVENTURE 2003 Manual

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Replacing bearing shells, output end

– Center the new bearing shells (both smooth) with the assembling
sleeve 600.29.044.050
side so the bearing shells can be pushed in easily. The bearing shells
should protrude 1-2 mm on the other side of the assembling sleeve to
make it easier to position them in the engine case.
– Position the bearing shells on the output end of the case such that
the end gap on the bearing shells points to the marks
disassembling.
– Press in the bearings from the outside to the inside through the
assembling sleeve up to the stop using the press mandrel
600.29.044.050
3
–
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE OTHERWISE
THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII OF THE
CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS
BEARING SHELLS ARE SEATED
–
THE ASSEMBLING SLEEVE SERVES AS A STOP
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION

Replacing bearing shells, generator end

– Center the new bearing shells (smooth – on the bottom, grooved –
on the top) with the assembling sleeve 600.29.044.050 – same
procedure as for the bearing shells, output end (see above).
– Position the bearing sleeves at the generator end of the case with the
bearing shell end gap pointing to the marks
disassembling. Do not cover the oil bore.
– Press the bearings into the engine case half from the outside to the
inside through the assembling sleeve up to the stop using the special
tool 600.29.044.050.
–
ALWAYS PRESS IN BEARING SHELLS FROM THE OUTSIDE TO THE INSIDE OTHERWISE
THEY WILL NOT BE POSITIONED CORRECTLY AND THE BEARING RADII OF THE
CRANKSHAFT WEBS WILL PRESS AGAINST THE BEARING SHELLS
BEARING SHELLS ARE SEATED
–
THE ASSEMBLING SLEEVE SERVES AS A STOP
BEARING SHELLS ARE SEATED IN THE CORRECT POSITION
–
IF THE BEARING SHELLS ARE INCORRECTLY ALIGNED OR IF SMOOTH BEARING
SHELLS ARE PRESSED IN ON TOP
COOL THE PISTONS AND LUBRICATE THE TIMING CHAIN WILL BE INTERRUPTED
LEADING TO SERIOUS ENGINE DAMAGE
NOTE:
– After replacing all friction and roller bearings, dismount the spraying
nozzles and oil nozzles and clean the oil ducts with compressed air to
make sure they are not clogged.
– Coat the friction bearings with Molycote grease.
Apply Loctite 243 to the spraying nozzles and oil nozzles and tighten to 10 Nm.
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. The assembling sleeve is beveled on one
3
.
! CAUTION
2
MM BELOW THE EDGE OF THE BEARING BORE
! CAUTION
2
MM BELOW THE EDGE OF THE BEARING BORE
,
THE OIL SUPPLY TO THE SPRAYING NOZZLES TO
.
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2
made when
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THIS IS WHY THE
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.
IT IS NOT REMOVED UNTIL THE
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4 made when
!
.
THIS IS WHY THE
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IT IS NOT REMOVED UNTIL THE
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