KTM 1190 RC8 EU 2008 User Manual

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30/ENGINE - WORK ON INDIVIDUAL PARTS 112
– Check the thickness of intermediate clutch discs .
Intermediate disk - thickness
New condition 1.95… 2.05 mm (0.0768… 0.0807 in)
Wear limit 1.85 mm (0.0728 in)
» If the intermediate clutch discs do not meet specifications:
– Change all intermediate clutch discs.
– Check clutch facing discs  for discoloration and scoring.
» If there is discoloration or scoring:
– Change all clutch facing discs.
– Check the thickness of clutch facing discs .
Clutch facing disc - thickness
New condition 2.92… 3.08 mm (0.115… 0.1213 in)
Wear limit 2.85 mm (0.1122 in)
» If the clutch facing discs do not meet specifications:
– Change all clutch facing discs.
– Check pretension ring  and support ring  for damage and wear.
» If there is damage or wear:
– Change the pretension ring and support ring.
– Check inner clutch hub  for damage and wear.
» If there is damage or wear:
– Change the inner clutch hub.
– Check the components of clutch pressure booster  for damage and wear.
» If there is damage or wear:
– Change all components of the clutch pressure booster.
– Check the springs of outer clutch hub  for damage and wear.
» If there is damage, wear or play in the direction of rotation:
– Change the outer clutch hub.
20.24Checking the shift mechanism
200458-01
– Check shift forks  at leaf  for wear.
Shift fork
Thickness at leaf 4.85… 4.95 mm (0.1909…
0.1949 in)
Clearance in the sliding gear
groove: New condition
0.35… 0.55 mm (0.0138…
0.0217 in)
Clearance in the sliding gear
groove: Wear limit
0.70 mm (0.0276 in)
» If the measured value does not equal the specified value:
– Change the shift fork and the idler/fixed gear pair.
– Check shift grooves  of shift drum  for wear.
» If the shift groove is worn:
– Change the shift roller.
– Check the seat of the shift drum in grooved ball bearing .
» If the shift roller is not seated correctly:
– Change the shift drum and/or the grooved ball bearing.
– Check grooved ball bearing  for stiffness and wear.
» If the grooved ball bearings do not move freely or are worn:
– Change the grooved ball bearing.
– Check shift rollers  for an ovality, surface damage and cracking.
» If the shift roller is oval, or shows signs of surface damage or cracks:
– Change the shift roller.

KTM 1190 RC8 EU 2008 Specifications

General

Brand	KTM
Model	1190 RC8 EU 2008
Category	Motorcycle
Language	English