Assembly Of Engine Housing; Clutch Release Shaft - KTM 250 1998 Repair Manual

7
6
A
5.3 Assembling the engine housing
– Remove engine fastener from engine work stand.
– Check that both dowels are in proper place in right-hand housing and that trans-
mission shaft stop discs have been mounted.
– Apply light coat of grease to sealing surfaces of the housing and position new gasket.
– Grease shaft seal rings in left-hand half and place left-hand half in position.
– Position screws and tighten with 8 Nm (6 ft.lb).
– Gently knock crankshaft with plastic hammer and check easy running of shafts.
– Fix engine in work stand.

5.4 Clutch release shaft

– Apply grease to needle cages and seal ring, and mount clutch release shaft.
– Insert retaining bracket
– Coat screw
1
2
5.5 Shift mechanism
– Place locating spring with bent leg upwards into engine housing.
– Insert collar sleeve
– Coat collar screw
– Insert locating lever with roll upwards and fix all parts with collar screw.
– Hook locking spring
3
5
4
– Mount roller locking device (plastic part) to shift roller. Ensure that the flat parts
are not in the middle. Pull locking lever from shift roller.
– Mount driver for shift roller
– Coat allan head screw
– Grease assembled shift shaft and push into bearings together with stop disc until
slide plate contacts driver for shaft roller.
– Now squeeze, and push shift shaft in to the stop.
– Check that legs of return spring surround both left and right side of housing nose
– Mount the foot shift lever and shift through all gears. Then remove the foot shift
lever.
1
coat collar screw with Loctite 242 and mount.
2
with Loctite 242 and use it to fix the clutch release lever spring.
3
into spring with collar upwards.
4
with Loctite 242.
5
to lever.
6
.
7
with Loctite 242 and mount.
5
3
A
.