KTM 400-660 LC4 1998-2005, Repair Manual

Page: 63 / 501

Repair manual KTM LC4
Art.-Nr
. 3.206.014 -E
5-5E
Working on the left half of the housing
Remove shaft seal rings and heat housing half to approx. 150° C by
means of a hot-plate.
Needle bearing of counter shaft
1
Press in new needle bearing from inside until flush.
Shaft seal ring of kickstarter shaft 2
Press in new shaft seal ring from outside with sealing lip facing inwards
until flush.
Grooved ball bearing of the balancer shaft
3
.
Use an extractor 151.12.017.000 and insert to remove the grooved ball
bearing from the housing half.
Shaft seal ring of crankshaft
4
Press in new shaft seal ring from outside with sealing lip facing inwards
until flush.
Retaining plate for main shaft grooved ball bearing
5
If the retaining plate has been removed, use Loctite 243 for the two
countersunk bolts during assembly.
Oil ducts
6
Use compressed air to clean all oil ducts. Ensure that the oil ducts are
not clogged.
Roller bearing of crankshaft
7
From outside press crankshaft roller bearing inwards using a suitable
mandrel.
Press in new roller bearing from inside up to the stop.
Grooved ball bearing of main shaft
8
Press in new grooved ball bearing from inside up to the stop.
!
CAUTION
!
D
O NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE
RETAINING PLATE
5
TO AVOID A BENDING OF THE PLATE
,
WHICH WOULD RESULT IN
EXCESSIVE AXIAL PLAY OF THE MAIN SHAFT
.
Needle bearing of kickstarter shaft
9
Press in new needle bearing from inside until flush.
Bypass valve
Test valve piston, tight fit and pressure spring for damage.
Minimum length of the pressure spring
bk
: 25.00 mm (1 in)
NOTE: The opening pressure of the bypass valve is reduced when the
length of the pressure spring decreases below 25 mm (1 in). This
reduces the oil pressure and causes engine damage.
Ensure that neither the lubrication bore of the roller bearing
A
nor the
oil ducts of the oil pumps are clogged.
– After the housing half has cooled down, check bearings for tight fit.
– Finally, insert both dowels so that the dowel with internal diameter
15.4 mm (0.616 in) is mounted at the rear (swingarm pivot).
10
A
1
2
3
4
5
6
7
8
6
9
3