KTM 200 User Manual

Disassembling and checking the water pump
– Remove the 2 bolts of the water pump cover and take off the water
pump cover.
– Pull the water pump and the O-ring out of the clutch cover.
– Clamp the water pump with the water pump wheel facing upwards
into the vise (use protective jaws).
! CAUTION !
T
O PREVENT DAMAGING OF THE WATER PUMP DRIVING WHEEL, NEVER CLAMP THE
WATER PUMP DRIVING WHEEL ITSELF INTO THE VISE
.
– Remove collar bolt
1 together with the washer.
– Pull the water pump wheel
2 upwards off the water pump shaft 3.
–Take the water pump shaft out of the vise and pull the water pump
shaft out of the water pump housing
4.
Shaft seal ring of the water pump shaft
5
Use a screwdriver to lever the shaft seal ring out of the water pump
housing.
Apply Loctite 648 to the outside of the new shaft seal ring and press it
into the housing with the label facing inwards.
Grooved ball bearing of the water pump shaft
6
The shaft seal ring 5 must be removed to exchange the grooved ball
bearing. Use an appropriate mandrel to press the grooved ball bearing
out of the water pump housing
4.
Press a new grooved ball bearing all the way into the seat. Apply Loctite
648 to the outside of a new water pump shaft seal ring and insert it with
the label facing inwards.
Water pump driving wheel
7
The water pump driving wheel should not turn on the water pump
shaft.
Check the teeth of the water pump driving wheel for wear.
Preassembling the water pump
–Grease the shaft seal ring 5 and the grooved ball bearing 6 of the
water pump shaft and insert the water pump shaft into the water
pump housing
4.
– Clamp the water pump shaft into the vise (use protective jaws).
! CAUTION !
TO PREVENT DAMAGING OF THE WATER PUMP DRIVING WHEEL, NEVER CLAMP THE
WATER PUMP DRIVING WHEEL ITSELF INTO THE VISE
.
– Put the water pump wheel
2 on the shaft, apply Loctite 243 to the
bolt
1 and mount bolt and washer.
– Place preassembled water pump and new O-ring into clutch cover.
– Fix water pump cover with 2 short bolts.
5-11C
2
1
5
4
6
3
7

KTM 200 Specifications

General

Brand	KTM
Model	200
Category	Engine
Language	English