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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
Mounting shift mechanism
– Place locating spring with bent leg upwards into engine housing.
– Insert collar sleeve into spring with collar upwards.
– Coat collar screw
1 with Loctite 243.
– Insert locating lever
2 with roll upwards and fix all parts with collar
screw.
– Hook locking spring
3 to lever. The other end of the retaining spring
must abut the casing nose
B.
– Mount roller locking device 4 (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
5.
– Coat allan head screw
6 with Loctite 243 and mount.
NOTE: From model 2002 on driver for roller
5 and locking piece 4 are
made of aluminium.
–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
A.
–Mount the foot shift lever and shift through all gears. When shifting
through the gears, turn the countershaft. Then remove the foot shift
lever.
Mounting kickstarter
– Place spacing washer on the stop face an place preassembled
kickstarter shaft in bearing bore in such a way that the locking pawl is
outside the release plate.
NOTE: If the kickstarter shaft is mounted correctly, the visible end of the
starter spring must point forward (see photo).
– Hook spring hanger
7 to starter spring, coat screw 9 with
Loctite 243, tighten starter spring approx. 90° clock-wise and fix
spring pawl with allan head screw.
– Adjust starter spring so that the distance to the kickstarter shaft is the
same all around.
– Place starter intermediate gear
8 with the high collar (see sketch)
showing towards the engine casing on to the bearing.
– Slip on stop disc (17.2x25x1 mm) and mount circlip with the sharp
edge showing upwards.
6-4C
1
2
3
4
5
6
A
7
8
9
B
LOCTITE 243