KTM 690 LC4 2007 - Mounting the Piston, Cylinder and Cylinder Head; Mounting the Rotors

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Repair manual KTM 690 LC4 Art.-No. 3.206.045-E
Mounting the rotors
– Slide the rotor 1 onto the crankshaft, paying attention to the shaft
key.
– Mount the lock washer and nut; hold the rotor with special tool
750.29.091.000
2 while you tighten the nut (A/F 27 mm) to 100
Nm.
– Check the distance between the pulse generator and the rotor: 0.7
mm; if the distance deviates, loosen both screws
3, correctly
position the sensor
4 and tighten the screws to 10 Nm.
Mounting the piston, cylinder and cylinder head
– Liberally oil special tool 750.29.015.102 5 and piston (including
the piston rings), push the piston into the special tool as far as
possible without using force. The piston will protrude a few
millimeters on the other side.
! CAUTION
!
T
HE PISTON RINGS SHOULD NOT PROTRUDE FROM THE SPECIAL TOOL.
– Mount the piston and special tool on the liberally oiled cylinder and
slide in the piston.
NOTE:
– if the parts are well-oiled, you will be able to push the piston into
the cylinder with your finger.
– The arrow
6 on the piston will point towards the front, i.e. the
exhaust end.
– Apply a thin coat of Loctite 5910 (584.29.059.200) on the housing
joints
7.
– Mount a new cylinder base gasket.
– Only push the piston out of the bottom of the cylinder far enough to
allow the piston bolt to be inserted.
NOTE:
– push the piston bolt into the conrod bearing as gently as possible.
– Cover the engine case with a cloth or paper towel to prevent the
piston bolt lock ring from falling in while being mounted.
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