KTM 690 LC4 2007, Repair Manual

Page: 36 / 95

5-3
– Mount all bearing retainers, lock screws with Loctite 648 and
tighten to 5 Nm.
– Press in a new shaft seal ring for the crankshaft
1
and the shift
shaft
2
with the open side towards the inside until it sits flush.
– Remove the bypass valve, inspect for score marks or seizing marks,
measure the length of the pressure spring.
Minimum length of the pressure spring: 25 mm
– Oil the bypass valve and mount with the spring, screw in the plug
with a new seal ring and tighten to 20 Nm.
– Apply Loctite 648 to the thread of the spraying nozzle 50
3
and
tighten to 6 Nm.
– Mount the dowels again.
– Mount the diaphragm support plate
8
and the diaphragm
9
again.
Use some Loctite 243 on the threads of the screws (M3x8) and
tighten.
NOTE: the diaphragm support plate is curved and must point away
from the diaphragm.
! CAUTION !
– A
N INCORRECTLY MOUNTED DIAPHRAGM SUPPORT PLATE WILL LEAD TO POOR
PERFORMANCE AND EXCESSIVE OIL CONSUMPTION OR LEAKS
.
– M
AKE SURE NO
L
OCTITE
243
DRIPS BETWEEN THE DIAPHRAGM AND THE
DIAPHRAGM SUPPORT PLATE OTHERWISE ITS FUNCTION WILL BE IMPAIRED
.
1
2
3
4
4
5
6
7
Left case half
– Pry the shaft seal rings out of the crankshaft
1
and the shift shaft
2
without damaging the case.
– Remove the spraying nozzle
3
.
– Thoroughly clean the case, removing any residual
sealant. Blow compressed air through all oil bores.
– Remove all bearing retainers
4
.
– Remove the plug
5
and take the pressure spring
6
and bypass valve
7
out of the hole.
– Pull the dowels out of the case.
– Unscrew the diaphragm support plate
8
(TX 10)
and remove together with the diaphragm.
– Heat the case in the oven to approx. 150° C and
tap on a level wooden board, causing the bearings
to drop out of the bearing seats. Any bearings that
remain in the case must be pressed out with a
suitable press/drift tool.
– Push new bearings into the bearing seats while
the engine case is still hot. Press all the way in
from the inside to the outside, using a suitable
press/drift tool if necessary.
NOTE:
– To avoid damage, make sure the case lies flat
when pressing in the bearings.
– Always press in bearings on the outer ring or the
bearings will be damaged in the process.
– Check the bearings for a tight fit when the case
has cooled.
8
8
9