KTM 125 SX 2010, Owner'S Manual

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Art.- No. 3.206.088-E
Repair manual KTM 250 / 300
Servicing the right engine housing half
– Remove all shaft seal rings and use an oven to heat the casing half
to approx. 150°C.
The bearings usually fall out of their seat of their own accord by
knocking the housinq half on a plane piece of wood when the housing
has a temperature of 150° - 180° C. At this housing temperature, the
new (cold) bearings can be inserted in the bearing seats without
pressing.
Grooved ball bearing of crankshaft
1
Press the old grooved ball-bearing inwards. Press in the new grooved
ball bearing from inside up to the stop.
Grooved ball bearing of main shaft
2
Press in the new ball bearing from inside up to the stop.
Grooved ball bearing of countershaft
3
Press in the new grooved ball bearing from downward to the stop.
Grooved ball bearing of the shift roller
4
Remove bolt
A
and press bearing towards the inside. Press in the new
ball bearing from the inside to the stop and secure the retaining bolt
with
Loctite 243.
Needle bushing of the shift shaft
5
Press the old needle bushing inwards, press in the new needle bushing
flush from the outside.
Grooved ball bearing of centrifugal timer
6
Use a self-made "supporting plate" to support the puller to avoid
damage to the housing (see illustration).
Pull out the bearing using a Ø 5-8 mm inside puller 151.12.018.100.
Press in the new grooved ball bearing to the stop.
Bearing bolt kickstarter intermediate gear
7
Experience has shown that it is never necessary to replace the bearing
bolt. It is not recommended to mount a used bearing bolt in a new
housing half, as it is practically impossible to remove it without causing
damage.
Kickstarter release plate
8
Secure the screws with Loctite 243 when changing the release plate.
Crankshaft seal ring
9
Press in the new shaft seal ring from the outside with the sealing lip
facing inward, until flush.
– Finally check clear passage of the crankshaft ball bearing lubrication
bore
B
.