KTM 200 User Manual

Repair manual KTM 125 / 200
Art No 3.206.005 -E
Crankshaft
– When replacing the roller bearing, the inner crankshaft ring must also
be renewed.
– Heat special tool 584.29.037.037 on a heating pad up to approx.
150°C and slip it on the inner ring immediately. Press the special tool
together tightly so as to obtain a good heat transfer and pull the
inner ring off the crankshaft.
–To mount the new inner ring, heat the special tool again to approx.
150°C, engage the inner ring and slip it on the crankshaft journal
immediately.
! CAUTION !
NEVER CLAMP THE CRANKSHAFT WITH A STUD OR WEB IN THE VICE
, AND NEVER TRY
TO KNOCK THE BEARING INNER RING FREE
. THE CRANKSHAFT WEBS MAY BE
COM
-PRESSED AND THE CON
-ROD PLUG AND BEARING MAY BE DAMAGES
, THEREBY
MAKING THE CRANKSHAFT UNUSABLE
.
NOTE: Distance adjustment of the main bearings is not requested.
– Place the crankshaft on a roller block or the like, and impact-test the
crankshaft journals at their outer ends, using a test gage.
run out of crankshaft journals: max. 0.02 mm (0.0008 in.)
Crankshaft webs – measure outer dimension
– Crankshaft webs – measure outer dimension with a sliding gauge as
illustrated.
Crankshaft webs – outer dimension = 55 mm ± 0.05 mm
Piston
If a used piston is to remain in service then the following should be
checked:
1. Piston running surface: Check for pressure marks (seizing marks)
minor friction marks can be removed with a fine abrasive stick.
2. Piston ring grooves: The piston rings must not get jammed in the
grooves. For cleaning the grooves, use an old piston ring or abrasive
paper (grain size 400).
3. The piston ring locating pins must be firmly seated in the piston and
must not be worn out.
4. Check piston rings for wear and check end gap.
– The piston is measured at the piston skirt, transverse to the piston pin
10 mm from the lower edge, as shown in the illustration.
– The smallest cylinder diameter minus the largest piston diameter
determines the piston fitting clearance.
Piston fitting clearance: 0,06 mm (125) / 0,055 mm (200)
Piston ring end gap
– Insert pisto ring into the cylinder and adjust. Piston ring must be
approx. 10 mm (0.5 in) from top of cylinder.
– The end gap
B can now be checked which a feeler gauge.
End gap max. 0.40 mm (0.015 in)
NOTE: If the end gap is greater check piston and cylinder for wear. If
piston and cylinder wear are within the permitted tolerance limits,
replace the piston ring.
5-4C

KTM 200 Specifications

General

Brand	KTM
Model	200
Category	Engine
Language	English