Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
Working on the right-hand housing half
– Remove all shaft seal rings and use an oven to heat the casing half to
approx. 150°C.
Grooved ball bearing of crankshaft
1
Press old grooved ball-bearing inwards. Press in new ball bearing to the
stop. The open side of the ball cage must be towards the bottom
(outside) of the case.
Grooved ball bearing of main shaft
2
Press in new ball bearing from inside up to the stop.
!
CAUTION
!
DO NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE
RETAINING BRACKET
3 TO AVOID A BENDING OF THE BRACKET
, WHICH WOULD RESULT
IN EXCESSIVE AXIAL PLAY OF THE MAINSHAFT
.
Grooved ball bearing of countershaft
4
Press in new grooved ball bearing from downward to the stop. The open
side of the ball cage must be face inwards.
Grooved ball bearing of the shift roller
5
Remove retaining screws A and press bearing inwards. Press in new ball
bearing from inside to the stop and secure retaining screws with Loctite
243.
Needle bushing of the shift shaft
6
Press old needle bushing inwards, press in new needle bushing flush from
the outside.
Grooved ball bearing of centrifugal timer
7
The bearings usually fall out of their seat of their own accord by knocking
the housinq half on a plane piece of wood when the housing has a
temperature of 150° C. If necessary use a 6 mm internal bearing extractor
and guide hammer (see illustration). Press in new grooved ball bearing to
the stop.
Bearing bolt kickstarter intermediate gear
8
Experience has shown that it is never necessary to replace the bearing
bolt. It is not recommended to mount a used bearing bolt in a new
housing half, as it is practically impossible to remove it without causing
damage.
Kickstarter release plate
9
When replacing the release plate, secure the flat-head screws with Loctite
243.
Crankshaft seal ring
bk
Press in new shaft seal ring from the outside, with sealing lip facing
inward, until flush.
Stop screw kickstarter
bl
When mounting the stop screw, it must be secured with Loctite 243. Do
not forget new copper seal ring.
Retaining bracket
3
When replacing the retaining bracket, the two collar screws are to be
secured with Loctite 243.
– Finally check clear passage of the crankshaft ball bearing lubrication
bore
S.
5-2C
1
2
3
4
5
6
7
8
9
10
A
A
7
S
11
