KTM 250 EXC, Owner'S Manual

Page: 134 / 410

5-19E
6
7
8
9
5
12
11
10
1
3
4
2
B
A
Checking the kickstarter for wear
Take all components off the kickstarter shaft and clean them.
Kickstarter gear
1
Check the toothing for wear and the bearing for clearance.
Kickstarter idler gear
2
Check the bearing for clearance and seizing marks. Check the toothing
for wear. It is constantly engaged with the outer clutch hub.
Kickstarter ratchet gear
3
Check the inclined surface and the toothings for wear.
Kickstarter shaft
4
Check bearing positions and toothings for wear and damage. Check the
oil bore for the kickstarter gear for unobstructed passage.
Preassembling the kickstarter shaft
– Clamp the kickstarter shaft
4
with the toothed end facing upward
into a vise (use protection jaws).
– Mount stop disc
5
, needle bearing
6
and kickstarter gear
1
with
the locking teeth facing downward.
– Slip on the stop disc
7
and mount the circlip
8
with the sharp
edge facing upward.
– Mount the driving hub
9
such that the recess is located above the
bore in the kickstarter shaft.
– Mount kickstarter spring
bk
and hook starter spring leg into
kickstarter shaft bore.
– Unclamp the kickstarter shaft.
– Slip the kickstarter ratchet gear
3
on the kickstarter shaft such that
the marks
A
mates with the oil duct
B
in the kickstarter shaft.
– Mount the ratchet gear spring
bl
and the stop disc
bm
on the
kickstarter shaft.