KTM 125 SX 2010, Owner'S Manual

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Art.- No. 3.206.088-E
Repair manual KTM 250 / 300
Mounting the clutch discs and pressure cap
– Oil the thrust bearing
1
, and slide it over the drive shaft.
– Oil the lining discs before mounting.
– Beginning with one lining disc, mount alternately 9 lining discs
(= 2.70 mm / 0.10 in) and 8 intermediate discs (= 1.20 mm /
0.047 in), with a lining disc forming the final layer upwards.
NOTE: Mount the clutch disks with the sharp edge facing up.
– Place pressure cap into position; fit the clutch springs, the spring
retainer and the collar bolts.
– Tighten the collar bolts crosswise. Do not apply more than 10 Nm to
prevent damaging the threads in the inner clutch hub.
Mounting the clutch cover
– Make sure the 3 dowels are mounted in the engine housing.
– Grease the shaft seal ring and kickstarter shaft support and fix the
clutch cover gasket with a small amount of grease.
– Apply silicone to area
A
and carefully mount the preassembled
clutch cover. Turn the crankshaft slightly to allow the centrifugal
timer to engage in the primary pinion.
NOTE: Some of the gaskets already have an incorporated silicone track.
If so, no silicone must be applied to area
A
.
– Fit the collar bolts (see sketch for bolt lengths) and tighten to 10
Nm.
– Then check the easy running of all shafts.
– Check the seal groove on the outer clutch cover for damage, clean
and mount the outer clutch over together with the gasket (see illust-
ration of screw length).
NOTE: If the clutch cover cannot be mounted, verify whether or not the
kickstarter spring has been positioned correctly.