KTM 250 SX-F 2005, Repair Manual

Page: 48 / 125

5-3
1
2
3
4
5
6
7
A
B
Right casing half
Remove the shaft seal ring and the bearing fixing screws, heat the
casing half in the oven to approx. 150° C.
– Roller bearing for the crankshaft
1
Press in the roller bearing from the outside with a suitable driver.
Press in a new roller bearing from the inside up to the stop.
– Grooved ball bearing for the main shaft
2
Press in the grooved ball bearing from the outside with a suitable
driver. Press in a new grooved ball bearing from the inside up to the
stop.
– Grooved ball bearing for the countershaft
3
Press in the grooved ball bearing from the outside with a suitable
driver. Press in a new grooved ball bearing from the inside up to the
stop.
– Grooved ball bearing for the shift drum
4
Press in the grooved ball bearing from the outside with a suitable
driver. Press in a new grooved ball bearing from the inside up to the
stop.
– Needle bearing for the shift shaft
5
Press in the needle bearing from the outside. Press in a new needle
bearing from the inside until flush.
– Needle bearing for the timing train idler shaft
6
Pull the Needle bearing out of the casing half with a bearing
extractor. Press in a new bearing up to the stop.
– Shaft seal ring for the crankshaft
7
Press in a new shaft seal ring (open side on the inside) until flush.
– When the casing half has cooled, check the bearings for a tight fit.
– Apply Loctite 243 to the bearing fixing screws and tighten to 10 Nm.
– Make sure there are no score marks or seizing marks on the oil
pump housing.
– Make sure the oil ducts are not clogged.
NOTE: remove the jets and the bypass valve to clean the oil ducts and
check whether they are clogged.
– Apply Loctite 243 to the oil jet 70
A
and tighten to 3 Nm.
– Apply Loctite 243 to the oil jet 150
B
and tighten by hand.