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Be sure to contain any diesel fuel that spills as a result of this process. Replace if any cracks are discovered. Starter intermediate gear Check clearance of starter intermediate gear. Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points Check return surface for wear renew, if strongly notched. Press in new ball bearing to the stop.


Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch. Clean the combustion chamber surface and check for cracks and other damage.

Show all sx mxc exc sx mxc exc. Page Assembly Mainshaft C Transmission Secure mainshaft or countershaft in the vice using soft jaw-covers. Measure the crank pin and the main journal Check the condition of the crank pin and the main journal. If the engine must be run, make sure the area is well ventilated. For changing the locking pawl, press bearing needle kickstarter shaft.

When the gap of starter reel attaches the end of the starter rope, stop the reel with your finger and pull the rope out with an awl as show below in figure a. Check there is sufficient fuel in the tank and the fuel valve is in the open position b.

Note the direction of rotation. As a result of this disregard of our rules caused by person casualty and equipment damaged, our company does not assume any responsibility.

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Release the hose clamp of the fuel line on the pump side. Page Trouble Shooting If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Page Carburetor Adjustment C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. Grooved ball bearing of crankshaft Press old grooved ball-bearing inwards.

KTM EXC Repair Manual


Damaged or worn reed paddles must be replaced. Add the stiffener bolts to the crankcase cover for reducing vibration and noise, which should be tightened after other bolts around crankcase cover tightened. Place the reel into the case. Crankcase cover bolt tightening N. Turn the screw in the drain plug counter clockwise until fuel flows.

Repeat this step until the unit starts and runs. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.

Crankshaft roller bearing Press old roller bearing inwards, fragments by heraclitus pdf press in new ball bearing to the stop with the open side of ball cage downwards outside. Warm oil drains quickly and completely. Drain out the fuel from the fuel tank.

Reassemble the rocker arm assembly. Clean or replace dirty filter elements. Measure the clearance between the outer rotator of the lube oil pump and the lube oil pump body on the crankcase cover. Page Cleaning Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. This range is influenced by the position of the air control screw.

Replace the lube oil pump if the clearance exceeds the permitted limit. Always replace damaged filter elements.

Features no rectifi- cation, only an over-voltage regulation. They may remain in the shift roller. Page Assembly Countershaft Transmission Secure mainshaft or countershaft in the vice using soft jaw-covers. Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft.

The crankshaft bearing has been pressed into the cylinder block. Check diameter in several corresponding places to see if cylinder in worn oval. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. Pull the recoil starter or engage the electric starter until the fuel flow is steady. Furthermore, be sure to tighten the crankcase cover bolts with the specified tightening torque below.

The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. It will also help reduce air pollution. Exhaust gas contains poisonous carbon monoxide.

Coating check crank journals. Insert gearshift rails into the casing bores as far as they will go. Release the joint between the fuel line and fuel tank. Check that the fuel filter is not clogged. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench.