They may remain in the shift roller. Just print it out and take it with you into the garage or workshop. Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.
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. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. Production model years: 1998, 1999, 2000, 2001, 2002,2003, 2004, 2005. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. Crankshaft roller bearing Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards outside. Production model years: 2005, 2006,2007, 2008, 2009,2010. Kickstarter shaft Check for signs of wear and damage.
Replace all 6 springs if applicable. Press in new ball bearing to the stop. Instant download 2009 Ktm 400 Ktm 450 Ktm 530 Workshop Service Repair Manual, Fix it! Features no rectifi- cation, only an over-voltage regulation. It is specifically written for the do-it-yourselfer as well as the experienced mechanic. Damaged or worn reed paddles must be replaced. This range is influenced by the position of the air control screw.
In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. The hard dirt can be removed before washing with the help of a soft water jet. Check diameter in several corresponding places to see if cylinder in worn oval. Dismounting of the shift lock —. Remove gears and check the following for wear: — Needle bearing — Mainshaft and countershaft pivot points including idler gears — Shift dogs and gear wheels — Tooth faces of all gears —. Keep Your Motorcycle Running Smoothly. In the case of a significant deviation from the nominal value: —.
Locking pawl Check for signs of wear and damage. Starter intermediate gear Check clearance of starter intermediate gear. Filling in of transmission oil: — Remove the plug and top up with engine oil 15W-50 i. Just print it out and take it with you into the garage or workshop. Control rollers — Check clearance of bearings.
Keep Your Motorcycle Running Smoothly. Minimum length: 199 mm new: 199. Grooved ball bearing of crankshaft Press old grooved ball-bearing inwards. Save yourself Big money by doing your own repairs! For changing the locking pawl, press bearing needle kickstarter shaft. 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. Parting of engine housing halves — Top ignition-gear upwards and remove all 11 housing screws. The connection between the positive pole of the battery and the positive terminal of the capacitor marked + is made with a test lamp —.
Insert gearshift rails into the casing bores as far as they will go. All repair procedures are covered A-Z. Check toothing of control rollers for signs of wear. Mounting clutch discs and pressure cap — Oil the thrust bearing , and slide it over the drive shaft. Engine Cylinder Ø 67,500 - 67,512 67,513 - 67,525 72,000 - 72,012 72,013 - 72,025 78,000 - 78,012. The manual has detailed illustrations and step by step instructions.
. All diagnostic and repair procedures are covered. Keep Your sportmotorcycle Running Smoothly. Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft. It is specifically written for the do-it-yourselfer as well as the experienced mechanic.
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. Production model years: 2003, 2004, 2005,2006. 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 —. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. Crankshaft — Insert crankshaft from above through grooved ball bearing and push carefully as far as stop. The manual has detailed illustrations and step by step instructions.
Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch. Mixing ratio 2-stroke motor oil : super fuel 1:40 —. Remove gears and check the following for wear: — Needle bearing — Mainshaft and countershaft pivot points including idler gears — Shift dogs and gear wheels — Tooth faces of all gears —. . . . .