KTM 2003 950 Adventure User Manual

6-9
1
2
3
4
5
6
7
8
9
bk
Primary pinion
– Mount the woodruff key for the primary pinion in the shaft groove (if
dismounted).
– Mount the primary pinion
1 with the longer collar towards the rear.
The bore for the pickup ring must face towards the outside.
– Mount the gear wheel of the balancer shaft
2 with the collar facing
the back (up to the 2004 model).
– From the 2005 model: slide on the preassembled spreader drive,
making sure the drive wheel and tensioning wheel do not fall apart;
pull out the pin.
! CAUTION !
T
URN THE BALANCER SHAFT UNTIL THE MARKS ON GEARS FOR THE CRANKSHAFT
3 AND BALANCER SHAFT 4 COINCIDE AS SHOWN IN THE ILLUSTRATION. MAKE
SURE THE TIMING CHAINS DO NOT GET CAUGHT
.
NOTE: when the marks coincide the first cylinder of the engine is in
the TDC position.
– Slide a 30.3 x 50 x 2 mm spacer washer
5 and a needle bearing 6
on the clutch shaft.
– Mount the gear for the oil pump drive on the back of the outer
clutch hub. The gear is secured by 3 needle rollers.
Outer clutch hub
– When slipping the outer clutch hub onto the shaft, leave enough
room for the pickup ring
7 which is held in place by a pin.
! CAUTION !
–
T HE PIN ON THE PICKUP RING MUST ENGAGE IN THE HOLE OF THE PRIMARY PINION .
–T
HE PICKUP RING IN
CARBURATOR AND INJECTION MODELS ARE
DIFFERENTIATED BY THE POSITION OF THE
"TOOTH GAP"; THEY CANNOT BE
INTERCHANGED
.
– After mounting the ring gear on the crankshaft, push the outer
clutch hub up to the stop, moving the oil pump wheel back and
forth to make the procedure easier.
– Mount a 33.2 x 46 x 2 disk and nut
8 (46 mm) on the primary
pinion (LH thread). Apply Loctite 243 to the nut and tighten to
130 Nm.
– Mount a 20.2 x 33 x 1.5 mm disk and nut
9 on the balancer shaft.
Apply Loctite 243 to the nut and tighten to 150 Nm (up to the
2004 model).
– Mount the washer 20.2x34x1 mm and the spring washer
30.5x46.5x0.6-1.5, apply Loctite 243 to the nut 9 (A/F 30 mm) on
the balancer shaft and mount, tighten the nut to 120 Nm (from the
2005 model).
! CAUTION !
T
HE GEAR WHEEL AND BALANCER SHAFT ARE PRESTRESSED STARTING WITH THE
2005 MODEL; THE NUT ON THE BALANCER SHAFT MAY ONLY BE TIGHTENED TO
120 NM OTHERWISE THE SPREADER DRIVE WILL BE DAMAGED.
– Screw on the pickup
bk. Apply Loctite 243 to the bolts (M6x16) and
tighten to 10 Nm. Press the cable duct into the recess in the case.
NOTE: the gap between the pickup and the pickup ring must be between
0.6 and 1.0 mm (950) or between 0.4 and 0.6 mm (990).

KTM 2003 950 Adventure Specifications

General

Brand	KTM
Model	2003 950 Adventure
Category	Motorcycle
Language	English