KTM 125 SX 2010, Owner'S Manual

Page: 284 / 899

1
3
6
7
A
8
9
bk
6-4
Art.- No. 3.206.088-E
Repair manual KTM 250 / 300
LOCTITE 243
1
2
3
4
5
Mounting the shift mechanism
– Slip the disc
2
, the locking lever
3
, the locking spring sleeve
4
and the locking lever spring
5
onto the bolt
1
(M5x20).
– Apply Loctite 243 to the thread of the screw
1
and mount all parts
at one time.
– Slide the shift locating drum
6
onto the shift roller. Please note that
the flat portions are eccentric. Here, the locking lever has be drawn
away from the shift roller.
– Coat allan head bolt
7
with Loctite 243 and mount.
– Grease the pre-mounted shift shaft at the bearing positions and push
into the bearings together with the stop disk until the shift rail
touches the driver for the shaft roller.
– Now squeeze, and push shift shaft in to the stop.
– Check that the legs of the return spring surround both the left and
right side of the 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 the kickstarter shaft
– Oil the bearing bore for the kickstarter shaft.
– Insert the preassembled kickstarter shaft into the bearing bore such
that the ratchet gear is positioned behind the release plate.
– Attach the spring hanger
8
to the starter spring, apply Loctite 243
to the thread of screw
9
(M6x10), pretension the starter spring
approx. 90° in a clockwise direction and fix the spring hanger to 10
Nm.
– Adjust the starter spring so that the distance to the kickstarter shaft
is the same all around.
– Oil the starter idler
bk
on the inside and mount on the journal with
the high collar facing the engine housing.
– Slip on the stop disc (17.2x25x1 mm) and mount the circlip with
the sharp edge showing upwards.