KTM 250 1998, Repair Manual

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5.6 Kickstarter
– Place spacing washer on the stop face an place preassembled kickstarter shaft in
bearing bore in such a way that the locking pawl is outside the release plate.
– Hook spring hanger
1
to starter spring, coat allan head screw with Loctite 242,
tighten starter spring approx. 90° clock-wise and fix spring pawl with allan head
screw.
– Adjust starter spring so that the distance to the kickstarter shaft is the same all
around.
– Place starter intermediate gear
2
with the high collar (see sketch) showing
towards the engine casing on to the bearing.
– Slip on stop disc and mount circlip with the sharp edge showing upwards.
5.7 Primary drive, clutch
– Grease crankshaft seal ring.
– Put the oiled O-ring onto the crankshaft and mount the distance bushing with
the chamfer facing the crank web.
– Insert woodruff key into crankshaft.
– Place primary gear onto crankshaft with collar downwards.
– Apply Loctite 242 to thread.
– Fit locking washer and hexagon nut (left hand thread) by hand.
– Put the inner ring onto the main shaft with the collar facing downwards, then
mount the oiled needle cage
3
.
– Mount outer clutch hub and stop disc
4
.
– Mount inner clutch hub, new lock washer and hexagon nut to main shaft.
– Position clutch holder
5
and tighten hexagon nut with 100 Nm (74 ft.lb.).
– Remove the clutch holder and secure the hexagon nut by bending both brackets
of the lock washer upwards.
– Block primary drive with gear segment
6
and tighten primary gear hexagon nut
with 150 Nm (110 ft.lb.).
– Remove gear segment and check easy running of primary drive by turning
crankshaft.
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