950ADVENTURE2003
REPAIR MANUAL
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.009-E
KTM Group Partner
950ADVENTURE
REPAIR MANUAL
1SERVICE-INFORMATIONS
2GENERAL INFORMATION
3REMOVING AND REFITTING ENGINE
4DISASSEMBLING ENGINE
5SERVICING INDIVIDUAL COMPONENTS
6ASSEMBLING ENGINE
7ELECTRICAL
8FUEL SYSTEM
9TROUBLE SHOOTING
10 CHASSIS
11 TECHNICAL SPECIFICATIONS
12PERIODIC MAINTENANCE SCHEDULE
13WIRING DIAGRAMS
14
15
16
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
–Put the index into the binder.
–Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder.
–Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder.
–Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual.
–Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.
–Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!CAUTION !
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD
TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER
MOTORCYCLES UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally.
KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349.
NOTE to table:
–Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.009-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
–Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.
–Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible.
–Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual |
Page |
Current text |
Correct text |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman |
Company/work shop |
|
|
|
|
|
2-1 |
|
|
|
|
|
|
|
|
|
|
|
|
GENERAL INFORMATION |
2 |
||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INDEX |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.2-2 |
|
|
||
|
|
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-3 |
|
|
||
|
|
SLS-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-4 |
|
|
||
|
|
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-5 |
|
|
||
|
|
SPECIALTOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-6 |
|
|
||
|
|
SPECIALTOOLS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-7 |
|
|
||
|
|
BLEEDING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-9 |
|
|
Art.-Nr. 3.206.009-E
Repair manual KTM LC8
2-2
2
3 4
|
bn |
|
bo |
bk |
bl |
|
9 |
bm |
8 |
|
|
7 |
|
3.206.009-E |
|
|
|
br |
|
8 |
|
|
|
|
|
Art.-Nr. |
|
bp |
|
bq |
bs |
|
|
bt |
cl |
1 |
|
LC8 |
5 |
6 |
|
||
KTM |
|
|
|
|
|
manual |
cm |
|
cn |
|
|
Repair |
|
|
Pressure pump 1 draws engine oil from oil tank 2 through oil filter 3 and the oil return valve 4 and pumps it past the pressure relief valve 5 through the oil filter 6 into the annular groove
7.
The main bearing 8, the conrod bearings 9 and the spraying nozzle bk (front timing chain) are supplied with oil through holes in the crankshaft. An oil duct leads to spraying nozzle bl (piston cooling), the timing chain tensioner bm, the camshaft bn and the oil pressure switch bo in the front cylinder.
Another oil duct leads from the annular groove to a distributor groove bp in the clutch cover. From there an oil duct leads to the spraying nozzle bq (piston cooling). Another oil duct supplies the timing chain tensioner br, the spraying nozzle bs (timing chain) and the camshaft bt on the rear cylinder with oil. Another oil duct leads to the oil line ck that lubricates the transmission gears. The suction pump cl draws the oil from the oil sump cn through the screen cm into the oil tank 2.
ck
2-3
Intake system
Fresh air is drawn into the filter box through the intake snorkel 1, past the carburetors 2 and through the air filter 3. The cleaned air is conducted to the combustion chamber through the carburetors and intake ports.
1 |
|
|
3 |
2 |
2 |
|
2-4
Secondary air system
The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize.
If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture).
|
1 |
|
|
|
2 |
3 |
3 |
|
4 |
4 |
4 |
|
||
3.206.009E- |
|
|
Art.-Nr. |
|
|
KTM LC8 |
|
|
Repair manual |
|
|
2-5
3
2 |
2 |
|
1 |
Closed thermostat
The thermostat is closed if the temperature of the cooling liquid drops below 75° C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 and the thermostat 2.
5
6
4
7
3
2 2
1
Open thermostat
The thermostat 3 opens at 75° C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2, the aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator cap 5. The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold. The fan 7 switches on at 102° C.
2-6
Art.-Nr. 3.206.009-E
1 |
2 |
3 |
4 |
5 |
|
|
|
|
7 |
|
|
6 |
8 |
9 |
|
|
||
bk |
bl |
bn |
bo |
|
|
||
|
|
bm |
|
Repair manual KTM LC8
|
FIG |
PART NO |
DESCRIPTION |
|
|
|
|
|
|
|
1 |
151.12.017.000 |
Gear puller |
|
|
|
|
|
|
|
2 |
584.29.086.000 |
Pressing tool for swing arm bearing |
|
|
|
|
|
|
|
3 |
584.29.089.000 |
Chassis tool holder |
|
|
|
|
|
|
|
4 |
584.29.091.000 |
Press-in tool for bearing seat / rear wheel bearing |
|
|
|
|
|
|
|
5 |
584.29.092.000 |
Knock-out tool for bearing seat |
|
|
6 |
600.03.022.000 |
Center stand |
|
|
7 |
600.10.013.000 |
Sleeve for pressing tool for swim arm bearing |
|
|
8 |
600.29.018.000 |
Internal gear puller 28 mm |
|
|
|
|
|
|
|
9 |
600.29.020.000 |
Chain rivet tool |
|
|
|
|
|
|
|
10 |
600.29.055.000 |
Center stand lock |
|
|
|
|
|
|
|
11 |
600.29.055.100 |
Floor jack attachment |
|
|
|
|
|
|
|
12 |
600.29.056.000 |
Anvil dolly (for 584.29.086.000) |
|
|
|
|
|
|
|
13 |
600.29.057.000 |
Pliers for Öttiker clamps |
|
|
|
|
|
|
|
14 |
600.29.057.100 |
Pliers for spring-loaded band-type clamp |
|
|
|
|
|
|
2-7 |
|
|
|
|
|
|
|
|
|
bm |
|
|
|
|
|
|
|
|
|
|
|
|
5 |
|
|
|
|
|
|
1 |
|
|
|
|
|
|
|
|
|
|
2 |
|
3 |
|
|
|
|
|
|
|
|
|
4 |
|
|
|
|
|
|
|
6 |
bl |
7 |
|
|
|
|
|
|
|
|
|
bn |
bo |
bp |
bq |
|||
|
648 |
LOCTITE 243 |
|
||||||
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
9 |
bk |
|
|
|
|
|
|
|
|
|
|
|
|
br |
|
|
|
8 |
|
|
|
bt |
|
|
ck |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
cl |
|
|
|
bs |
|
|
|
|
|
|
cm |
cn |
co |
cp |
|
cq |
cr |
cs |
ct |
dk |
|
|
|
|
||||||
dl |
|
|
|
|
|
|
|
dr |
|
|
|
|
dn |
do |
|
|
|
|
|
|
|
|
|
|
|
dq |
|
||
|
|
|
|
|
|
dp |
|
|
|
|
|
dm |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Art.-Nr. 3.206.009-E
Repair manual KTM LC8
2-8
|
|
|
SPECIAL TOOLS – ENGINE |
|
|
|
|
|
|
|
|
|
|
|
|
FIG |
PART NO |
DESCRIPTION |
|
|
1 |
309098 |
Seal Three-Bond |
|
|
|
|
||
|
2 |
0113 080802 |
Crankshaft locking bolt |
|
|
|
|
||
|
3 |
151.12.017.000 |
Gear puller |
|
|
|
|
||
|
4 |
503.29.050.000 |
Bleeding syringe for hydraulic clutch |
|
|
|
|
||
|
5 |
560.12.001.000 |
Universal-engine work stand |
|
|
|
|
||
|
6 |
584.29.059.000 |
Loctite 648 green 20 ml |
|
|
|
|
||
|
7 |
585.29.005.000 |
Protection sleeve for shaft seal ring of water pump |
|
|
8 |
590.29.019.000 |
Valve spring mounter |
|
|
9 |
590.29.026.006 |
Limit plug gauge 6,05 mm |
|
|
10 |
590.29.041.000 |
Feeler gauge for valve clearance |
|
|
|
|
||
|
11 |
6 899 785 |
Loctite 243 blu 6 cm3 |
|
|
|
|
||
|
12 |
600.29.002.000 |
Engine holder for engine work stand |
|
|
|
|
||
|
13 |
600.29.003.000 |
Clutch holder |
|
|
|
|
||
|
14 |
600.29.005.000 |
Protection sleeve for shaft seal ring of output shaft |
|
|
|
|
||
|
15 |
600.29.009.000 |
Magneto extractor |
|
|
|
|
||
|
16 |
600.29.009.010 |
Protection bolt for magneto extractor |
|
|
17 |
600.29.010.000 |
Degree wheel |
|
|
18 |
600.29.011.000 |
Carburator synchronisation tool |
|
|
19 |
600.29.012.000 |
Plastigauge-measuring strips |
|
|
20 |
600.29.015.000 |
Piston ring mounting tool |
|
|
|
|
||
|
21 |
600.29.016.000 |
Setting gauge for float level |
|
|
|
|
||
|
22 |
600.29.018.000 |
Internal gear puller 28 mm |
|
|
|
|
||
|
23 |
600.29.031.000 |
Protection sleeve for crankshaft (for pulling of the primary gear) |
|
|
|
|
||
|
24 |
600.29.033.000 |
Puller for primary gear |
|
|
|
|
||
|
25 |
600.29.041.000 |
Valve spring mounter insert |
|
|
|
|
||
|
26 |
600.29.043.010 |
Pressing tool for seal of clutch release shaft |
|
|
27 |
600.29.043.020 |
Pressing tool for seal of output shaft |
|
|
28 |
600.29.043.030 |
Pressing tool for seal and bearing of shifting shaft |
|
|
29 |
600.29.043.040 |
Pressing tool for seal of water pump |
|
|
|
|
||
|
30 |
600.29.043.050 |
Pressing tool for seal of balancer shaft |
|
|
|
|
||
|
31 |
600.29.044.050 |
Pressing tool for main bearings (In/out) |
|
|
|
|
||
|
32 |
600.29.046.028 |
Pressing tool for supporting bearing (In) |
|
|
|
|
||
|
33 |
600.29.073.000 |
Spark plug wrench 16 mm |
|
|
|
|
||
|
34 |
600.29.075.000 |
Special nut for conrod |
|
|
|
|
||
|
35 |
600.29.081.000 |
Special tool for cylinder head nuts |
|
|
36 |
600.29.082.000 |
Holder for water pump wheel |
|
|
37 |
600.29.083.000 |
Special nut for cylinder head nuts |
|
|
|
|
|
|
2-9
Checking the oil level of the hydraulic clutch
To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove bolts and cover together with the rubber
1boot 1. The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary add SAE 10 biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).
! CAUTION !
ONLY USE SAE 10 BIODEGRADABLE HYDRAULIC OIL TO REFILL THE MASTER
CYLINDER. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH
MINERAL OILS!
2
A
Bleeding of the hydraulic clutch
For bleeding, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove bolts and take off cover together with rubber bellows 1. At the slave cylinder of the clutch, remove the bleeder nipple. At its place, mount the bleeder syringe 2 which is filled with biodegradable hydraulic oil (e.g. Motorex Kupplungs-Fluid 75).
Refill oil, until oil is discharged from the bore A of the master cylinder in a bubble-free state. Make sure that the oil does not overflow.
! |
CAUTION |
! |
HAVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER CYLINDER, USE SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY (EX. MOTOREX KUPPLUNGS- FLUID 75); NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.
3-1
INDEX
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Art.-Nr. 3.206.009-E
Repair manual KTM LC8
Art.-Nr. 3.206.009-E
Repair manual KTM LC8
|
|
|
|
3-2 |
|
|
|
Removing the engine |
|
|
|
|
||
|
|
|
– |
Screw the center stand 600.03.022.000 onto the frame 1 and jack |
|
2 |
|
||
|
|
|
up the motorcycle on a firm, even surface. |
|
|
|
|
– Remove the left bump rubber and lock the center stand with the lock |
|
|
|
|
||
|
|
|
|
600.29.055.000 2. |
NOTE: if available, use the center stand already on the bike.
– Unlock the seat lock with the ignition key and remove.
1
3 |
3 |
4 |
|
||
|
|
|
3 |
|
4 |
–Remove the bolts 3 on the left and right of the front side covers, disconnect the front turn signal, pull the tank vent hoses off of the fuel tank and remove the side covers.
–Open the tank cover, unscrew the fixing bolts 4 and remove the upper tank compartment.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
– |
Remove the bolts 5 on the lower tank compartment and the fuse |
|
5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
box, take the cover off the fuse box and dismount the lower tank |
|||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
compartment. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
– |
Close the fuel cocks, disconnect the gasoline hoses, unscrew the |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
upper 6 and lower 7 fixing bolts on both fuel tanks and remove the |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
6 |
|
|
|
|
6 |
|
|
|
|
|
|
|
tanks together with the lower vent hoses. |
|||
|
|
|
|
|
|
|
|
|
|
|
|
|
||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
NOTE: it is easier to disconnect the gasoline hoses if you remove the |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
front bolts on the underride protection and fold the engine guard down. |
|
|
|
|
|
|
5 |
|
|
|
|
|
|
|
|
|
7 |
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
– Drain the engine oil from the oil tank and the engine: see page 12-4. |
|||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
– |
Remove the 4 bolts 8 on the underride protection and take off the |
|
9 |
|
|
|
|
underride protection. |
|
|
|
|
– |
Remove both bolts 9 on the front cover and take off the cover. |
|
|
|
|
|
|
8
–Open the lid on the battery compartment and disconnect the battery terminals bk (starting with the negative pole).
–Take out the battery and remove the upper battery cover.
10
10
3-3
1
4
2
3
4
5
6
8
7
–Unscrew the bolts 1 and remove the intake snorkel 2 together with the frame from the air filter box.
–Disconnect the vent hose and the EPC hose and remove the upper half of the air filter box.
–Turn the intake trumpet 3 in a clockwise direction and remove. Remove air filter.
–Unbolt both side covers on the lower air filter box and remove the clamps on the carburetor connection boot.
–Detach the EPC hoses 4 from both carburetors and pull the hoses out of the lower air filter box.
–Remove both vent hoses from the carburetors.
–Lift both carburetors, carefully draw the cable for the idle speed adjustment and the gasoline hose through the openings in the lower air filter box.
–Detach the fuel hoses from the carburetors.
–Pull the carburetor connection boots off of the intake manifolds.
–Detach the SLS valve 5 from the lower air filter box, pulling the thin hose from the intake manifold and the thick hose from the valve. Remove the valve.
–Remove the EPC valve 6 from the lower air filter box and disconnect.
–Tilt up the carburetors and fasten to the handlebar with a wire or rubber band. They do not need to be completely dismounted.
–Take the lower air filter box out of the frame.
NOTE: cover the intake ports with a cloth to prevent any parts from falling inside.
–Unscrew both nuts 7 on the front exhaust manifold flange on the cylinder head, loosen the exhaust clamp 8 on the front exhaust manifold, pull the front exhaust manifold out of the rear exhaust pipe and remove.
–Unscrew the rear exhaust manifold from the cylinder head.
3-4
2 |
2 |
4
6
3
Art.-Nr. 3.206.009-E
6
–Disconnect the electric connections from the fan motor and the temperature switch 1.
– Drain the cooling liquid from the radiator and engine: see page 12-16.
–Detach the water hoses from the radiator (special pliers 600.29.057.100) and unscrew the radiator 2 .
NOTE: fan and radiator shield do not need to be dismounted from the radiator.
–Pull off the oil lines from the oil tank to the valve covers 3 and the return line 4 (special pliers 600.29.57.100), unscrew the oil lines from the oil terminal 5 and pull out. Remove the O-rings.
–Loosen the fixing bolts 6 on the oil tank, remove the oil tank and carefully pull out the oil line.
Repair manual KTM LC8
–Disconnect the side stand switch 7 and take the cable out of the cable clips.
–Loosen the two bolts and the nut 8 and remove the side stand.
8
7
–Unscrew the clutch slave cylinder 9 and the chainguard bk and pull the locking pin out of the pushrod.
–Dismount the chain roller and chain securing guide.
9
10
3-5
–Unscrew the nut on the wheel spindle, pull out the rear wheel spindle, take the chain off of the rear sprocket and place over the side of the bracket 1. Remove the chain from the engine sprocket.
1
–Detach the connector 2.
–Remove the engine vent hose 3, discarding the hose clamp.
2
3
2
5
6
–Unscrew the positive starter engine cable and draw out the wiring harness.
–Detach connector 4 on the starter relay.
–Pull out the gasoline pump vent hose 5 towards the bottom.
–Unscrew the ground connection 6.
8
8
7
9
–Disconnect the fuel hose 7.
–Loosen the bolts on the side support 8 and the nut on the bolt 9, pull out the bolt and remove support together with the battery case.
– Unscrew the front oil line bk.
10
3-6
–Use the trolley jack to position the attachment 600.29.055.100 on the engine, insert the bolt 1 through the front of the engine bracket and fasten with the nut. Screw one of the bolts 2 on the rear of the side stand fixture and slightly lift the engine.
1
2
– Remove the bolt 3 and tilt the foot brake pedal to the side.
3
Art.-Nr. 3.206.009-E
–Unscrew the ground wire connection 4.
–Detach the connector from the pulse generator 5.
4
5
Repair manual KTM LC8
|
|
|
|
|
|
|
– |
Detach the connector from the oil pressure switch 6, the |
|
6 |
|
|
|
|
|
||
|
|
|
|
|
|
|
temperature sensor 7 and from the front 8 and rear ignition coil. |
|
|
|
|
|
8 |
|
|
||
|
|
|
|
|
Remove any cable clips necessary. |
|||
|
|
|||||||
|
|
|
|
|
|
|
|
|
7
–Pull the bolt 9 out of the lower support (if necessary, raise or lower the engine slightly).
–Loosen the nut on the swing arm pivot bk and knock out the swing
10 |
arm pivot with a suitable pipe. |
|
|
|
|
–Pull the engine towards the front with the trolley jack, lower and pull away towards the side.
–Disconnect all hoses and lines from the engine.
9
3-7
1
2
3
5
4
6
7
–Before mounting the engine, attach the water, SLS and vacuum hoses (Öttiger clamps - special pliers 600.29.057.000 or spring-loaded band-type clamps - special pliers 600.29.057.100)
–Position the swing arm and fix with the swing arm pivot on the right and a suitable pipe on the left.
–Lift the engine into the frame with the trolley jack, insert the sealing washer in the rear exhaust flange and secure with copper paste if necessary.
–Guide the chain along the side of the pinion and insert the swing arm pivot 1, screw on the nut but do not tighten yet.
–Insert the bolt 2 in the lower support (raise or lower the engine slightly if necessary).
–Remove the trolley jack attachment 600.29.055.100 from the engine.
–Plug the connector on the oil pressure switch 3, the temperature sensor 4 and the front and rear ignition coil 5. Use cable clips to fasten the wiring harnesses.
–Screw on the ground wire connection 6.
–Attach the pulse generator connector 7.
–Position the foot brake pedal, apply Loctite 243 to the bolt 8 and tighten to 25 Nm.
8