KTM 250 SX - Manual (Page 59)

Repair manual KTM 250 / 300 / 380
Art No 3206004 -E
Mounting shift mechanism
– Place locating spring with bent leg upwards into engine housing.
– Insert collar sleeve into spring with collar upwards.
– Coat collar screw
1 with Loctite 243.
– Insert locating lever 2 with roll upwards and fix all parts with collar
screw.
– Hook locking spring 3 to lever. The other end of the retaining spring
must abut the casing nose B .
– Mount roller locking device 4 (plastic part) to shift roller. Ensure that
the flat parts are not in the middle. Pull locking lever from shift roller.
– Mount driver for shift roller 5 .
– Coat allan head screw 6 with Loctite 243 and mount.
NOTE: From model 2002 on driver for roller 5 and locking piece 4 are
made of aluminium.
– Grease assembled shift shaft and push into bearings together with
stop disc until slide plate contacts driver for shaft roller.
– Now squeeze, and push shift shaft in to the stop.
– Check that legs of return spring surround both left and right side of
housing nose A .
– Mount the foot shift lever and shift through all gears. When shifting
through the gears, turn the countershaft. Then remove the foot shift
lever.
Mounting kickstarter
– Place spacing washer on the stop face an place preassembled
kickstarter shaft in bearing bore in such a way that the locking pawl is
outside the release plate.
NOTE: If the kickstarter shaft is mounted correctly, the visible end of the
starter spring must point forward (see photo).
– Hook spring hanger 7 to starter spring, coat screw 9 with
Loctite 243, tighten starter spring approx. 90° clock-wise and fix
spring pawl with allan head screw.
– Adjust starter spring so that the distance to the kickstarter shaft is the
same all around.
– Place starter intermediate gear 8 with the high collar (see sketch)
showing towards the engine casing on to the bearing.
– Slip on stop disc (17.2x25x1 mm) and mount circlip with the sharp
edge showing upwards.
6-4C
1
2
3
4
5
6
A
7
8
9
B
LOCTITE 243