Left Housing Half - KTM 250 1998 Repair Manual

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1
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A
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4.1 Right-hand housing half
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Heat housing half to 150° C by means of hot plate.
G
ROOVED BALL BEARING OF CRANKSHAFT
4
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.
G
ROOVED BALL BEARING OF MAIN SHAFT
5
Press in new ball bearing from inside up to the stop.
6
D
O NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE RETAINING
BRACKET
AXIAL PLAY OF THE MAINSHAFT
G
ROOVED BALL BEARING OF COUNTERSHAFT
Press in new grooved ball bearing from downward to the stop. The open side of the
3
ball cage must be face inwards.
G
ROOVED BALL BEARING OF THE SHIFT ROLLER
7
Remove retaining screw
from inside to the stop and secure retaining screw with Loctite 242.
N
EEDLE BUSHING OF THE SHIFT SHAFT
Press old needle bushing inwards, press in new needle bushing flush from the outside.
G
ROOVED BALL BEARING OF CENTRIFUGAL TIMER
10
The bearings usually fall out of their seat of their own accord by knocking the hou-
sinq 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 illustra-
tion). Press in new grooved ball bearing to the stop.
B
EARING BOLT KICKSTARTER INTERMEDIATE GEAR
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.
K
ICKSTARTER RELEASE PLATE
When replacing the release plate, secure the flat-head screws with Loctite 242.
C
RANKSHAFT SEAL RING
Press in new shaft seal ring from the outside, with sealing lip facing inward, until
flush.
7
S
TOP SCREW KICKSTARTER
When mounting the stop screw, it must be secured with Loctite 242. Do not forget
new copper seal ring.
R
ETAINING BRACKET
When replacing the retaining bracket, the two collar screws are to be secured with
Loctite 242.
Finally check clear passage of the crankshaft ball bearing lubrication bore
4.2 Left-hand housing half
N
EEDLE BUSHINGS OF CLUTCH RELEASE
Remove seal ring from bore.
B
Knock needle bushings out of bore using a 12-16 mm extractor and guide hammer (see
illustration). Press in new needle bushings and seal ring in succession to the stop.
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2
!
CAUTION
3
TO AVOID A BENDING OF THE BRACKET
.
4
A
and press bearing inwards. Press in new ball bearing
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9
bk
bl
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B
!
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WHICH WOULD RESULT IN EXCESSIVE
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7
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.