KTM S5-E Repair Manual Download Page 1

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M O T O R C Y C L E S

REPARATURANLEITUNG

MOTOR

REPAIR MANUAL

ENGINE

MANUEL DE RÉPARATION

MOTEUR

S5-E / S5-T / S5-GS

3.97
ART. NR. 3.205.19

´97

Summary of Contents for S5-E

Page 1: ...M O T O R C Y C L E S REPARATURANLEITUNG MOTOR REPAIR MANUAL ENGINE MANUEL DE R PARATION MOTEUR S5 E S5 T S5 GS 3 97 ART NR 3 205 19 97...

Page 2: ...COMPLIANCE WITH THESE INSTRUCTIONS IS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB CAUTION NON COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCY CLES UNFIT...

Page 3: ...Reed valve housing S5 T 11 4 6 1 Reed valve housing S5 GS 11 4 7 Clutch cover 12 4 8 Kickstarter shaft 12 4 8 1 Preassembling of kickstarter shaft 13 4 9 Centrifugal clutch primary drive 13 4 10 Exch...

Page 4: ...e supports and carefully take engine out of the frame on the right side 1 0 SPECIAL TOOLS 2 0 REMOVING THE ENGINE 100 35 15 8 2 3 4 1 5 FIG DESCRIPTION PART NR 1 Holding wrench for flywheel and clutch...

Page 5: ...retaining springs 2 and lift off the ignition cover Take the rubber 3 out of the opening in the housing Disconnect the spark plug connector from the spark plug Remove the two screws 4 and washers and...

Page 6: ...and take off the base plate 3 3 Engine sprocket Remove the Seeger circlip and the washer behind the circlip and pull the engine sprocket off the countershaft Pull the flywheel rubber 2 off Remove scr...

Page 7: ...out of the piston without applying force Remove the piston Take the piston pin bearing out of the conrod eye 3 6 Kickstarter Remove screw 1 Hold the kickstarter and remove the kickstarter stop screw...

Page 8: ...INSIDE OF THE CLUTCH COVER Hold the clutch hub with the holding wrench and undo nut 1 LH thread Remove nut and washer Mount the extractor and pull off the clutch hub Remove the clutch drum together wi...

Page 9: ...N TERSHAFT CAN STICK TO THE INSIDE OF THE HOUSING Remove the housing gasket Take the stop disk off the countershaft CAUTION TO PREVENT DAMAGING OF THE SEALING SURFACES NEVER FORCE THE ENGINE HALVES AP...

Page 10: ...recess GROOVED BALL BEARING OF THE COUNTERSHAFT 6 Use a suitable mandrel to press the grooved ball bearing inwards Insert a new grooved ball bearing from inside pressing it all the way into the reces...

Page 11: ...the piston ring end gap B Align the piston ring with the piston approximately 10 mm 0 4 in below the upper cylinder edge Use a feeler gauge to measure the end gap B END GAP MAX 0 55 MM 0 022 IN IF TH...

Page 12: ...UALLY LOOSE THEIR TENSION DURING OPERATION AND BEGIN TO BREAK AT THE ENDS WHICH LEADS TO A REDUCED PERFORMANCE IN THE CASE OF DAMAGE THE ENTIRE REED VALVE HOUSING MUST BE REPLACED Mount reed valve hou...

Page 13: ...aft the teething facing the kick starter gear while at the same time hooking the ratchet gear spring into the ope ning 4 in the housing Put the Seeger circlip on the kickstarter shaft with the sharp e...

Page 14: ...he clutch linings Check the clutch shoe bolts 2 for tight fit CLUTCH DRUM Check the running surface 3 of the clutch drum for grooves and signs of wear Check the primary gear 4 for breakage and signs o...

Page 15: ...e shaft seal rings of the crankshaft and countershaft Heat the right housing half to approximately 100 C and mount it If necessary slightly tap the right housing half with a rubber hammer Grease the h...

Page 16: ...he ignition coil with 2 screws 1 After tightening the screws it should still be possible to move the ignition coil sideways Measure the distance between flywheel and ignition coil at points A with a f...

Page 17: ...the cylinder over the piston and remove the wooden fork 5 8 Cylinder head Put on a new cylinder head gasket and mount the cylinder head Mount the 4 nuts of the cylinder head and tighten with 10 Nm 7 5...

Page 18: ...the screws with 8 Nm 6 ft lb 5 10 Kickstarter Slide the kickstarter spring onto the kickstarter shaft and hook the end of the kickstarter spring into the recess in the clutch cover 2 Mount the plasti...

Page 19: ...illing plug 8 on the clutch cover and fill in 0 25 l gear oil SAE 80 Carry the engine into the frame Mount and tighten the engine bracket screws Mount carburetor Mount chain and fix it with master lin...

Page 20: ...mix ratio to be on the safe side Lubrication mixture lubrication Crankshaft bearing 2 grooved ball bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston rings 1 L rin...

Page 21: ...in Cylinder diameter bore max 39 026 mm 1 5368 in max 39 024 mm 1 5367 in max 39 024 mm 1 5367 in Piston fitting clearance max 0 070 mm 0 0028 in max 0 028 mm 0 001 in max 0 028 mm 0 001 in Piston rin...

Page 22: ...t of brake cables Check freeplay and operation of hand brake levers Check fork for function and tightness Service front fork completely Check steering head bearing clearance adjust Clean and grease st...

Page 23: ...Y C L E A K T I E N G E S E L L S C H A F T A 5 2 3 0 M a t t i g h o f e n P o s t f a c h 9 1 A u s t r i a I n t e r n e t h t t p w w w k t m c o a t F N 1 0 2 0 1 9 d L a n d e s g e r i c h t R...