KTM 250 SX-F 2005, Repair Manual

Page: 51 / 125

5-6
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
Measuring the outside dimension of the crankshaft webs
– Measure the outside dimension of the crankshaft webs using a
sliding gauge, as illustrated.
Outside dimension of the crankshaft webs = 54 mm ± 0.05 mm
Crankshaft bearings
– Fix the crankshaft in the vise with protective jaws.
– Heat the special tool 584.29.037.037 on a hotplate to approx.
150° C and immediately slip onto the inner ring. Firmly press the
special tool together to obtain a good heat transfer and pull the
inner ring off the crankshaft.
– To mount the new inner ring, heat the special tool to approx. 150° C
again, clamp around a new inner ring and immediately slip onto the
crankshaft journal.
– Make sure the new inner ring fits flush.
– After replacing the inner ring, measure the axial clearance of the
crankshaft.
! CAUTION !
N
EVER CLAMP THE CRANKSHAFT INTO A VISE WITH THE CRANKSHAFT JOURNAL AND
TRY TO STRIKE THE INNER BEARING RING
. T
HE CRANKSHAFT WEB WILL BE
PRESSED TOGETHER AND RENDER THE CRANKSHAFT USELESS
.
Axial clearance of the crankshaft
– Insert the crankshaft in the right casing half and mount the left
casing half.
– Mount the casing screws around the crankcase and tighten.
– Mount the dial gauge support on the engine case and measure the
axial clearance of the crankshaft.
Axial clearance: 0.25 - 0.35 mm
– Correct the axial clearance if the measured value does not
correspond to the setpoint value.
– To correct, remove the crankshaft and pull the inner ring off the
crankshaft on the ignition side using the special tool. Add or remove
compensating disks.
NOTE: Add compensating disks if the axial clearance is too large.
Remove compensating disks if the axial clearance is too small. Only
add compensating disks on the ignition side.