5-2
Repair manual KTM 690 LC4 Art.-No. 3.206.045-E
Right case half
– Pry the shaft seal rings out of the crankshaft 1
and the water pump shaft 2 without damaging
the case.
– Remove the spraying nozzle
3 and the oil jet 4.
– Remove the plate
5 on the engine ventilation.
– Thoroughly clean the case, removing any residual
sealant. Blow compressed air through all oil bores.
– Remove all bearing retainers
6.
– Pull the dowels out of the case.
– 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:
– Press the shift shaft bearing
7 in from the
outside to the inside until it sits flush.
– 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.
– Mount all bearing retainers, lock screws with
Loctite 648 and tighten to 5 Nm.
– Press in a new crankshaft seal ring 1 with the open side towards
the inside until it sits flush.
– Press in a new water pump shaft seal ring
2 with the open side
towards the outside until it sits flush.
– Inspect the oil pump housing
8 for score marks or seizing marks.
– Apply Loctite 648 to the spraying nozzle 50
3 and tighten to 6 Nm.
– Apply Loctite 648 to the oil jet 125
4 and tighten to 2 Nm.
– Mount the plate
5 on the engine vent, lock the screws (AH M5x12)
with Loctite 243 and tighten to 3 Nm.
– Mount the dowels again.
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