KTM 250 SX-F 2005, Repair Manual

Page: 63 / 125

5-18
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
Kickstarter
– Remove all parts from the kickstarter shaft and clean.
– Check the toothing on the kickstarter pinion
1
for wear and the
clearance of the mounting.
– Check the toothing of the kickstarter idler
2
for wear and the
clearance of the mounting.
– Check the ratchet surface and toothing of the kickstarter ratchet
gear
3
for wear.
– Check the pivot points and toothing of the kickstarter shaft
4
for
wear and damage. Make sure the oil bore for the kickstarter pinion
is not clogged.
Pre-mounting the kickstarter shaft
– Clamp the kickstarter shaft in a vise with the toothed end facing up
(use protective jaws).
– Mount the stop disk
5
and kickstarter pinion with the lock toothing
facing down.
– Mount the stop disk
6
and circlip
7
with the sharp edge facing up.
– Mount the kickstarter spring
8
, inserting the inner end in the hole
in the kickstarter shaft.
– Mount the driving hub
9
, pushing the recess over the end of
kickstarter spring.
– Unclamp the kickstarter shaft.
– Slide the kickstarter ratchet gear on the kickstarter shaft so that
mark
A
on the ratchet gear coincides with the hole
B
for the spring
in the kickstarter shaft.
– Mount the ratchet gear spring
bk
and stop disk
bl
on the kickstarter
shaft.
A
B
1
bl
bk
9
8
7
6
5
4
3
2