Clutch Discs, Pressure Cap; Clutch Cover - KTM 250 1998 Repair Manual

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5.8 Clutch discs, pressure cap

– Oil lining discs before mounting.
– Beginning with one lining disc, mount alternately 9 lining discs (≠ 2,7 / 0.1 in)
mm) and 8 intermediate discs (≠ 1,2 mm / 0.047 in), with a lining disc forming
the final layer upwards.
– Oil the push rod and insert it into the main shaft.
– Oil the thrust bearing
– Place pressure cap into position; fit clutch springs, spring retainer and collar screws.
– Tighten the collar screws crosswise. Do not apply more than 6 Nm (4.5 ft.lb.) to
prevent damaging of the threads in the inner clutch hub.

5.9 Clutch cover

– Check whether both dowels are mounted in clutch cover or engine housing.
– Grease kickstarter shaft seal ring and position clutch cover gasket. Secure gasket
with a little grease.
– Carefully position preassembled clutch cover and press into place, turning
crankshaft so that centrifugal timer can engage in the primary gear.
– Fit collar screws (see sketch for screw lengths) and tighten with 8 Nm (6 ft.lb.).
– Then check easy running of all shafts.
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and put it onto the main shaft.
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