KTM 250 SX-F 2005, Repair Manual

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– Insert the woodruff key in the crankshaft groove.
– Slip on the rotor.
– Mount the spring washer and nut. Tighten the nut to 60 Nm.
Mounting the piston and cylinder head
– Place the well-oiled piston on the cylinder and clamp the piston
rings together with the piston ring compressor 600.29.015.000.
– Gently tap on the piston ring compressor with a plastic hammer from
above to make it fit flush against the cylinder.
– Carefully tap the piston into the cylinder with the hammer handle,
making sure the piston rings do not jam.
! CAUTION !
IF THE PISTON RING COMPRESSOR PRESSES THE PISTON RINGS TOGETHER
PROPERLY AND FLUSH AROUND THE ENTIRE CYLINDER
,
YOU WILL BE ABLE TO PUSH
THE PISTON INTO THE CYLINDER BY TAPPING LIGHTLY WITH THE HAMMER HANDLE
.
E
XCESSIVE FORCE USUALLY DAMAGES THE PISTON RINGS
.
– Mount a new cylinder base gasket and thrust bushing.
– Slide the piston out of the bottom of the cylinder until you can push
in the piston pin.
NOTE:
– You should easily be able to push the piston pin into the conrod
bearing.
– The arrow mark
1
on the piston must point to the front, i.e. the
exhaust side.
– Cover the engine case with a cloth or towel to prevent the piston pin
lock ring from falling in while mounting.
– Mount the piston pin lock ring.
NOTE: the gap must be on the top or bottom but not on the side.
– Attach a cable clip to the timing chain and pull it through the
timing chain compartment.
– Slide the cylinder onto the engine case.
6-10
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
1