KTM 250 SX-F 2005, Repair Manual

Page: 43 / 125

Separating the casing halves, removing the crankshaft and
transmission shafts
– Turn the engine over and remove all of the casing screws as well as
both nuts on the engine work stand holders.
– Lift off the left casing half; if necessary, gently tap on the shaft with
a plastic hammer.
! CAUTION !
D
O NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY THE HOUSING HALVES
APART SINCE THIS WILL DAMAGE THE SEALING AREAS
.
– Pull the bushing
1
and O-ring for the countershaft out of the
countershaft shaft seal ring, discarding the O-ring.
NOTE: the main shaft has a stop disk which usually adheres to the
bearing; be careful not to lose it.
– Lift the crankshaft out of the bearing.
– First pull out the upper springs
2
in the shift rails and then pull out
the shift rails
3
.
– Tilt the shift forks
4
aside and pull out the shift drum
5
; remove
the shift forks. If the lower springs do not stick to the shift rails,
remove them with a suitable tool.
– Move the engine case into the upright position and hold both
transmission shafts with one hand while you press the shafts out of
the bearing seats from behind with your other hand. Make sure the
engine case cannot fall off the mounting rack.
4-12
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
1
2
2
3
3
4
4
4
5