KTM 250 1998, Repair Manual

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A
B
C
D
4
1
8
7
2
9
3
5
6
V
ELOCITY INSERT
C
Check for firm mounting and for signs of damage.
I
NTAKE FLANGE
D
Check for cracks and other signs of damage.
4.13 Kickstarter
S
TARTER GEAR
1
Check clearance of starter gear.
S
TARTER INTERMEDIATE GEAR
2
Check clearance of starter intermediate gear.
L
OCKING PAWL
3
Check for signs of wear and damage.
For changing the locking pawl, press bearing needle
9
out of the kickstarter shaft.
K
ICKSTARTER SHAFT
4
Check for signs of wear and damage.
4.14 Assemble of kickstarter shaft
– Fix the kickstarter shaft
4
in a vice with the toothed end upwards (use covered
vice clamps).
– Mount ratchet spring
5
on kickstarter shaft as shown in the illustration.
– Place needle cage
6
in position, push starter gear over it, pressing locking pawl
3
inwards so that starter gear passes smoothly over it.
– Hook legs of the starter spring
7
into driving hub
8
, push both together on the
starter shaft, hook starter spring leg into kickstarter shaft bore
A
.
4
7
5
6
1
A