KTM 65 SX 2009, Руководство по ремонту

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CONTENTS
3
Removing the intermediate kickstarter gear...................... 56
Removing the shift shaft ................................................ 56
Removing the shift drum locating.................................... 56
Removing the locking lever............................................. 56
Removing the reed valve housing .................................... 57
Removing the left engine case section ............................. 57
Removing the shift rails ................................................. 58
Removing the shift drum ................................................ 58
Removing the shift forks ................................................ 58
Removing the transmission shaft..................................... 58
Removing the crankshaft................................................ 59
30/ENGINE - WORK ON INDIVIDUAL PARTS....................... 60
Work on the right section of the engine case .................... 60
Work on the left section of the engine case ...................... 61
Changing the conrod bearing .......................................... 61
Checking the crankshaft run-out on the bearing pin .......... 62
Removing the water pump .............................................. 63
Installing the water pump............................................... 63
Checking/measuring the cylinder..................................... 64
Checking/measuring the piston ....................................... 64
Determining the piston/cylinder mounting clearance ......... 65
Checking the piston ring end gap .................................... 65
Checking the reed valve housing, diaphragm and intake
flange........................................................................... 65
Disassembling the clutch ............................................... 66
Checking the clutch....................................................... 66
Premounting the clutch.................................................. 67
Checking the shift mechanism ........................................ 68
Preassembling the shift shaft.......................................... 69
Disassembling the main shaft ......................................... 69
Assembling the main shaft ............................................. 69
Dismantling the countershaft.......................................... 70
Assembling the countershaft........................................... 70
Checking the transmission.............................................. 71
Premounting the kickstarter shaft.................................... 72
30/ASSEMBLING THE ENGINE .......................................... 73
Installing the crankshaft................................................. 73
Installing the transmission shafts .................................... 73
Installing the shift forks ................................................. 73
Installing the shift drum................................................. 73
Installing the shift rails .................................................. 74
Installing the left engine case section.............................. 74
Installing the reed valve housing ..................................... 74
Installing the locking lever.............................................. 75
Installing the shift drum locating .................................... 75
Installing the shift shaft ................................................. 75
Installing the intermediate kickstarter gear....................... 76
Installing the kickstarter shaft ........................................ 76
Installing the primary gear.............................................. 76
Installing the outer clutch hub........................................ 76
Installing the clutch cover .............................................. 77
Mounting the water pump cover ...................................... 78
Installing the kickstarter................................................. 78
Installing the stator ....................................................... 78
Installing the rotor ......................................................... 78
Installing the piston....................................................... 79
Installing the cylinder .................................................... 79
Checking the X-distance................................................. 80
Setting the X-distance.................................................... 80
Adjusting the ignition..................................................... 81
Installing the generator cover.......................................... 81
Installing the distance bushing ....................................... 82
Installing the engine sprocket ......................................... 82
Installing the exhaust control valve.................................. 82
Installing the cylinder head ............................................ 82
Installing the exhaust control.......................................... 83
Installing the spark plug................................................. 84
Installing the oil drain plug............................................. 84
Installing the clutch pressure piece ................................. 84
Removing the engine from the universal mounting rack ..... 84
31/CARBURETOR ............................................................. 85
Removing the carburetor ................................................ 85
Installing the carburetor ................................................. 86
Disassembling the carburetor.......................................... 87
Assembling the carburetor.............................................. 89
Checking/setting the carburetor components .................... 91
Checking the jet needle.................................................. 91
Checking the throttle slide.............................................. 92
Checking the float needle valve....................................... 92
Checking the choke slide................................................ 92
Checking/setting the float level ....................................... 92
Carburetor - adjusting the idle speed ............................... 93
Emptying the carburetor float chamber ............................ 93
32/CLUTCH ...................................................................... 95
Checking the fluid level of hydraulic clutch...................... 95
Changing the hydraulic clutch fluid................................. 95
35/WATER PUMP, COOLING SYSTEM ................................ 96
Draining the coolant ...................................................... 96
Refilling coolant ............................................................ 96
Checking the antifreeze and coolant level ........................ 96
Checking the coolant level.............................................. 97
38/LUBRICATION SYSTEM ................................................ 99
Checking gear oil level ................................................... 99
Changing the gear oil ..................................................... 99
Draining the gear oil ...................................................... 99
Filling up with gear oil ................................................... 99
Adding gear oil............................................................ 100
39/IGNITION SYSTEM ..................................................... 101
Checking the ignition system ........................................ 101
Checking the short circuit button .................................. 101
Checking the ignition pulse generator ............................ 102
Checking the generator ................................................ 102
Checking the spark plug connector................................ 103
Checking the CDI controller .......................................... 103
Checking the ignition coil............................................. 103
TROUBLESHOOTING....................................................... 105
TECHNICAL DATA - ENGINE............................................ 107
Capacity - gear oil........................................................ 107
Capacity - coolant........................................................ 107
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 108
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 109
TECHNICAL DATA - CARBURETOR................................... 110
TECHNICAL DATA - CHASSIS .......................................... 111
Tires .......................................................................... 111
Capacity - fuel............................................................. 111
TECHNICAL DATA - FORK................................................ 112
SX.............................................................................. 112
XC.............................................................................. 112
TECHNICAL DATA - SHOCK ABSORBER ........................... 113
SX.............................................................................. 113
XC.............................................................................. 113
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 114
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