KTM 125 SX 2010, Owner'S Manual

Page: 259 / 899

Repair manual KTM 250/300
Art.- No. 3.206.088-E
1
2
3
– Remove the 4 collar nuts
1
on cylinder base and remove the
cylinder.
– Remove the cylinder base gasket.
– Cover the crankcase.
– Place piston on a wooden jig and remove both piston pin locking
pins.
– Expel the piston pin from the piston without exerting undue force.
Use a suitable mandrel if necessary.
– Remove the piston and the piston pin needle-bearing from the
conrod eye.
!
CAUTION
!
T
HE PISTON PIN MUST NEVER BE FORCED OUT WITH A PUNCH
. T
HIS WOULD
DAMAGE THE CONROD BEARING
.
NOTE:
2
PISTON RINGS ARE INSTALLED STARTING WITH THE
2005
MODEL
.
Dismounting the clutch cover
– Remove the collar bolts and the clutch cover including the gasket.
NOTE:
– The water pump cover
3
, the outer cover
2
and the cover lid
4
do
not need to be removed.
– The water pump and the centrifugal timer remain in the clutch cover.
5
6
Dismounting the pressure cap and the clutch discs
– Loosen the collar bolts
5
in a diagonally opposite sequence to
prevent wedging of the discs as the springs expand.
– Remove the collar bolts, springs and spring retainers.
– Take the pressure cap and the disc package out of the outer clutch
hub.
– Take the thrust bearing
6
off the drive shaft.
4-4
4