Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
Mounting clutch discs and pressure cap
–Oil the thrust bearing 1, and slide it over the drive shaft.
– Oil lining discs before mounting.
– Beginning with one lining disc, mount alternately 9 lining discs (≠ 2.70
mm / 0.10 in) and 8 intermediate discs (≠ 1.20 mm / 0.047 in), with
a lining disc forming the final layer upwards.
– 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.
Mounting 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.
NOTE: If the clutch cover cannot be mounted, verify whether or not the
kickstarter spring has been positioned correctly.
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