KTM 400-660 LC4 1998-2005, Repair Manual

Page: 233 / 501

10-8E
Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
1
1
2
3
S 2
2
5
5
6
6
5
S1
S1
S2
S2
S3
S2
S3
S2
6
4
4
2
7
8
9
bk
bk
bl
bl
Overhauling the rocker arm
– See page 10-2 Chassis to dismount the rocker arm.
– Remove all 4 seal ring tappets
1
(does not require a tool).
– Pry out all of the shaft seal rings
2
with a screwdriver without
damaging the housing.
– Pull out both bearing sleeves
3
(do not lose the washer
S
).
– Remove the two collar bushings
4
from the bearing link with a
bearing extractor (10 mm diameter) or knock them out with a driver
from the opposite side.
– Press both needle bushings
5
out of the holes with the
S1
pressing tool (584.29.085.000, smaller diameter), using the
S2
sleeve 584.29.087.000).
– Turn the pressing tool
S1
around and press in the new needle
bushings until flush.
NOTE: Press in each needle bushing from the respective side.
– Press out the bearing link 6 with the S3 pressing tool
(584.29.086.000, smaller diameter), using the S2 sleeve.
– Turn the
S3
pressing tool around and press in the new bearing until
flush; the bearing's outer ring will protrude 1 mm.
NOTE: If an
S
washer was installed and the bearing sleeves
3
were
not replaced, the washer can be used again. If the bearing sleeve on the
swing arm link needs to be replaced, make sure the rocker arm is
installed without any clearance at the swing arm. In case of clearance,
use a thicker washer.
Use the same procedure in the reverse order to mount the remaining
parts. The shaft seal rings can be pressed in with the back of the sleeve
S2
.
To mount the rocker arm, see page 10-2 Chassis.
Replacing the linkage bolt bearing in the frame
– See page 10-2 Chassis to dismount the rocker arm.
– Screw the nut
7
from the bearing bolt
9
on the linkage arm
8
,
remove the left linkage arm and pull out the bearing bolt from the
side.
– See page 10-3 Chassis to dismount the swing arm.
– Remove the right front footrest.
– Pry the right shaft seal ring
bk
out of the frame.
– Pull in the new needle bearings
bl
with the tool 584.29.088.044 by
tightening the nut
bm
. The two pressure disks
bn
on the tool with the
smaller diameter must point towards the bearing. Pull in the bearing
until the collar on the pressure disk rests against the frame sleeve.
– Use the disks from 584.29.093.000 to pull in the shaft seal rings.
Use the same procedure in the reverse order to finish mounting.
– See page 10-3 Chassis to mount the swing arm.
– See page 10-2 Chassis to mount the rocker arm.
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