KTM 1190 RC8 EU 2008 User Manual

CONTENTS 3
Preparing the engine for installation ................................ 72
Installing the engine ...................................................... 72
Setting the engine to ignition top dead center of the rear
cylinder ........................................................................ 76
Setting the engine to ignition top dead center of the front
cylinder ........................................................................ 76
30/DISASSEMBLING THE ENGINE..................................... 77
Clamping the engine into the engine work stand............... 77
Draining the engine oil................................................... 77
Removing the front valve cover ....................................... 77
Removing the rear valve cover......................................... 77
Setting the engine to ignition top dead center of the rear
cylinder ........................................................................ 78
Removing the starter motor ............................................ 78
Removing the oil filler tube ............................................ 78
Removing the heat exchanger ......................................... 79
Removing the rear timing chain tensioner ........................ 79
Removing the rear camshaft ........................................... 79
Removing the rear cylinder head ..................................... 80
Removing the rear piston................................................ 80
Setting the engine to ignition top dead center of the front
cylinder ........................................................................ 80
Removing the front timing chain tensioner....................... 80
Removing the front camshafts ........................................ 81
Removing the front cylinder head.................................... 81
Removing the front piston .............................................. 81
Removing the generator cover ......................................... 82
Removing the ignition pulse generator ............................. 82
Removing the torque limiter and idler.............................. 82
Removing the rotor ........................................................ 82
Removing the idler and timing chain on the left ............... 83
Removing the oil filter.................................................... 84
Removing the balancer shaft .......................................... 84
Removing the drive wheel of the balancer shaft ................ 84
Removing the gear position sensor .................................. 84
Removing the left suction pump ..................................... 85
Removing the water pump wheel..................................... 86
Removing the clutch cover ............................................. 86
Removing the idler and timing chain on the right.............. 86
Removing the clutch facing ............................................ 87
Removing the outer clutch hub ....................................... 87
Removing the primary gear ............................................. 88
Removing the force pump .............................................. 88
Removing the shift shaft ................................................ 89
Removing the shift drum locating.................................... 89
Removing the locking lever............................................. 89
Removing the left engine case ........................................ 90
Removing the crankshaft................................................ 90
Removing the middle suction pump ................................ 90
Removing the transmission shaft..................................... 91
Removing the oil spray tube ........................................... 92
Removing the timing chain rails of the right engine case
section ......................................................................... 92
Removing the timing chain rails of the left engine case
section ......................................................................... 92
30/ENGINE - WORK ON INDIVIDUAL PARTS....................... 93
Work on the right section of the engine case .................... 93
Removing the main bearing of the right engine case
section ......................................................................... 94
Selecting the main bearing shells.................................... 95
Installing the right main bearing ..................................... 95
Work on the left section of the engine case ...................... 96
Removing the left main bearing ...................................... 98
Installing the left main bearing ....................................... 98
Changing the conrod bearing .......................................... 99
Work on the clutch cover.............................................. 100
Changing the step bearing of the crankshaft................... 101
Checking the radial clearance of the bottom connecting
rod bearing ................................................................. 102
Checking/measuring the cylinder................................... 102
Checking/measuring the piston ..................................... 103
Checking the piston ring end gap .................................. 104
Checking the piston/cylinder mounting clearance............ 104
Work on the cylinder head ............................................ 104
Checking the cylinder head .......................................... 107
Work on the right idler ................................................. 108
Checking the timing assembly ...................................... 109
Preparing the timing chain tensioner for installation ....... 109
Checking the oil pressure regulator valve........................ 110
Checking the oil pumps................................................ 110
Checking the clutch..................................................... 111
Checking the shift mechanism...................................... 112
Preassembling the shift shaft........................................ 113
Dismantling the main shaft .......................................... 113
Dismantling the countershaft........................................ 114
Checking the transmission............................................ 115
Assembling the main shaft ........................................... 116
Assembling the countershaft......................................... 116
30/ASSEMBLING THE ENGINE ........................................ 118
Installing the timing chain rails of the left engine case
section ....................................................................... 118
Installing the timing chain rails of the right engine case
section ....................................................................... 118
Installing the oil spray tube .......................................... 119
Installing the transmission shaft ................................... 119
Installing the middle suction pump ............................... 120
Installing the crankshaft............................................... 120
Installing the left engine case....................................... 121
Installing the locking lever............................................ 122
Installing the shift drum locating .................................. 122
Installing the shift shaft ............................................... 122
Installing the force pump ............................................. 123
Installing the left suction pump .................................... 124
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 124
Installing the primary gear............................................ 125
Installing the outer clutch hub...................................... 125
Installing the clutch facing........................................... 126
Installing the idler and timing chain on the right ............ 127
Installing the clutch cover ............................................ 127
Installing the water pump wheel ................................... 128
Installing the gear position sensor ................................. 128
Installing the drive wheel of the balancer shaft............... 128
Installing the balancer shaft ......................................... 129
Installing the idler and timing chain on the left .............. 129
Installing the oil filter .................................................. 130
Installing the rotor....................................................... 130
Installing the torque limiter and idler ............................ 131
Installing the ignition pulse generator............................ 131
Installing the generator cover........................................ 131
Installing the oil drain plug........................................... 131
Installing the rear piston .............................................. 132
Installing the rear cylinder head.................................... 133
Installing the rear camshaft.......................................... 134

KTM 1190 RC8 EU 2008 Specifications

General

Brand	KTM
Model	1190 RC8 EU 2008
Category	Motorcycle
Language	English