Shift Mechanism, Transmission; Crankshaft - KTM 250 1998 Repair Manual

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3.13 Parting of engine housing halves
– Top ignition-gear upwards and remove all housing screws.
– Release engine mounting brackets on work stand.
– Lift left-hand housing half with suitable tools by on the bosses provided, or part
with a few light plastic mallet blows against the countershaft from the right-hand
housing half.
!
L
EVERING APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED
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FACES ARE EASILY DAMAGED
N : W
OTE ATCH GEAR SHAFT STOP DISCS

3.14 Shift mechanism, transmission

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– Pull out the shift rails and swing the shift forks aside.
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– Pull the shift roller out of the bearing seat.
– Remove the shift forks.
N : A
OTE LTHOUGH THE COUNTER SHAFT SHIFT FORKS ARE IDENTICAL THEY SHOULD BE REFITTED
IN THE SAME POSITION AS BEFORE IF REUSED
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– Push drive shaft approx. 30 mm upwards and remove countershaft
then possible to remove the mainshaft completely from bearing.
N : W
OTE ATCH COUNTERSHAFT STOP DISC TO PREVENT IT STICKING TO THE HOUSING

3.15 Crankshaft

– Pull crankshaft out of bearing seat (if necessary by tapping gently with a plastic
hammer).
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– Take distance bushing out of seal shaft ring and remove O-ring
– Clean all parts and check for wear, replace if necessary.
N : W
OTE HEN AN ENGINE IS COMPLETELY OVERHAULED IT IS RECOMMENDED THAT ALL GAS
, O-
KETS SHAFT SEAL RINGS AND RINGS ARE RENEWED
CAUTION
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TO PREVENT THEM STICKING TO INSIDE OF HOUSING
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HEREFORE MARK ACCORDINGLY UPON REMOVAL
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SINCE THE SEAL
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. It is
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