Repair manual KTM 125 / 200
Art No 3.206.005 -E
– Carefully unhook the kickstarter spring from bore 1 (pretensioned
spring) and release it.
– Rotate the kickstarter shaft approximately 1/4 turn counterclockwise
and pull it out of the housing. Keep in mind the stop disc behind !
– Undo 3 bolts and remove the gear shifting gate
2 together with the
ratchet carrier
3. Procede with care by watching out for the collar
bushing
4 on the ratchet carrier.
– The locking lever
5 need not be removed unless the engine housing
is exchanged.
– For this purpose, undo bolt
6, then remove the locking lever
together with the spring.
–Take the washer
7 out of the locking drum.
– Hold the locking drum
9 with the special tool, undo bolt 8 and
remove the bolt together with the washer.
– Pull the locking drum off the shift roller.
!
CAUTION
!
T
HE LOCKING DRUM MUST BE HELD WITH THE SPECIAL TOOL TO PREVENT DAMAGING
OF THE BUSHINGS ON THE DRIVING PINS OF THE SHIFT FORKS
.
Dividing the engine housing
– Swing the ignition side upwards and remove all 12 housing bolts.
– Undo the engine mounting device at the mounting rack.
– Lift the left housing half by the lifting points of the housing, using
appropriate tools, or separate it from the right housing half by lightly
tapping the countershaft with a plastic hammer.
!
CAUTION
!
T
O PREVENT DAMAGING OF THE SEALING SURFACES, DO NOT USE A SCREWDRIVER
OR SIMILAR TOOL TO LEVER THE HOUSING HALVES APART
!
– Remove the housing half and the gasket.
– Keep in mind the stop disc of the main shaft (can stick to the inside of
the housing).
4-8C
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