KTM 125 SX 2010, Owner'S Manual

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14
13
12
11
10
2
3
9
4
9
3
2
8
16
17
bl
bq
br
br
bq
bl
5-7
as of Model
2006
Model
2004
2005
– Mount and grease the O-rings (15x1.50 mm)
9
on the control flap and grease.
– Slightly grease the bearing sleeves
3
and plug them on the control flap.
– Mount the toothed segments
2
(the toothed segment with the cylindrical pin has to be mounted on the right side).
– On the right-hand side, mount the bearing bushing
bk
with the collar outside, the adjusting lever
bl
with the ball head on outside,
the overload spring
bm
with the short leg on outside and the spring sleeve
bn
to the control flap.
– Coat allan head bolt
bo
with Loctite 243 and bolt up about 5 revolutions, hook the short leg of the overload spring on to the
cylinder pin (see illustration) and tighten the allan head bolt.
– Mount the stop plate
8
on the left side. Do not tighten bolts
bq
+
br
yet as they will be used to adjust the exhaust control (mea-
surement Z).
– Turn the control rollers
1
in the cylinder in such a way the that ports are completely open and no edges protrude.
– Place preassembled control flap in the cylinder, engage the gear
segments in the control rollers in such a manner that, when the
control flap is open (pivoted right to the top), the markings of the
gear segments and the gear rollers coincide. Please check that the
two control rollers do not block the cross-section of the port when
the control flap is open.
– Coat the sealing surface thinly with silicon and mount intermediate
flange
bs
with 4 silicon O-rings (11.3x2.4 mm).
– Finally check the smooth running of the exhaust control system.
NOTE: It must be possible to push adjusting lever
bl
further upwards
against the spring force.