Checking The Freewheel (125 Duke); Work On The Left Section Of The Engine Case (200 Duke) - KTM 125 DUKE EU Repair Manual

16 ENGINE
» If there is damage or wear:
–
Replace the freewheel gear and/or the bearing.
–
Check toothing of the starter motor for damage and wear.
4
» If there is damage or wear:
–
Replace the starter motor.
–
Replace the O-ring of the starter motor.
5
–
Clamp the minus (negative) cable of a 12 Volt power supply to the starter motor housing. Briefly connect the positive cable of the
power supply to the starter motor connection.
» If the starter motor does not turn when you close the power circuit:
–
Replace the starter motor.

16.4.29 Checking the freewheel (125 Duke)

16.4.30 Work on the left section of the engine case (200 Duke)

–
Insert freewheel gear
wise; do not wedge!
–
Check the locking action of the freewheel gear.
» If the freewheel gear does not turn clockwise or if it does not lock counterclock-
wise:
–
Replace the freewheel.
304255-10
–
Remove all dowels.
–
Remove lock ring
–
Remove shaft seal ring
–
Remove oil nozzle
–
Remove any sealing mass remnants and clean the engine case section thoroughly.
–
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
–
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
–
Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing all the way to the
stop or so that it is flush.
304769-10
Info
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
–
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
–
Mount the dowels.
–
Press in shaft seal ring
it is flush.
into the freewheel hub by turning the freewheel gear clock-
1
.
1
of the shift shaft and
2
.
4
of the shift shaft with the open side facing inward so that
2
of the countershaft.
3
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