KTM 125 - Engine Technical Data (250;300); Engine Design and Piston Specifications (250;300); Fuel, Ignition, and Primary Drive Specifications (250;300); Transmission and Clutch Specifications (250;300)

Repair manual KTM 125 / 200
Art No 3.206.005 -E
5-14C
Kickstarter
Take all components off the kickstarter shaft and clean them.
Kickstarter gear
1
Check the bearing for play and grooves.
Intermediate kickstarter gear
2
Check the bearing for play and grooves.
Locking pawl
3
Check for wear and damage.
Kickstarter shaft
4
Check for wear and damage, paying particular attention to pivot points
and teeth. Check the lubrication bores for free passage.
Preassembling the kickstarter shaft
– Mount the locking pawl on the kickstarter shaft. Ensure that the mark
A on the locking pawl coincides with the bore B in the kickstarter
shaft.
– Clamp the kickstarter shaft
4 into the vise (use protective jaws) with
the teethed end facing upwards.
–Mount the stop disc
5 (17x24x1 mm) and the kickstarter gear 1
with the ratchet teeth facing downwards.
– Put the stop disc
6 (17x24x1 mm) on the shaft.
– Mount the circlip
7 with the sharp edge facing upwards.
– Mount the kickstarter spring
8; insert the inner end of the kickstarter
spring into the bore of the kickstarter shaft.
– Mount the driving hub
9; the slot must be positioned above the
inner end of the kickstarter spring.
–Take the kickstarter shaft out of the vise.
– Mount the ratchet gear spring
bk and the stop disc bl on the
kickstarter shaft.
A
B
1
6
7
8
9
5
12
11
10
3
4
2