KTM 125 - Shift Drum Locating Device

Repair manual KTM 125 / 200
Art No 3.206.005 -E
– Mount the rotor.
– Mount the detent edged ring and the nut.
– Hold the rotor with the holding spanner and tighten the hexagon nut
with 60 Nm / 44 ft.lb.).
Shift drum locating device
– Mount the locking drum 1 on the shift roller. Keep in mind that the
pin of the shift roller must engage in the corresponding recess of the
locking drum.
– Slide washer onto bolt
2, apply Loctite 243 on its thread and mount
the bolt. Block the locking drum with a special tool
(see picture), and tighten the bolt.
! 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
.
NOTE: If the locking lever hasn’t been removed, push it sideways
against the resistance of the spring when mounting the locking drum.
– Mount washer
3.
– Line the washer, the locking lever, the collar bushing (the small collar
facing the head of the bolt) and the locking spring upon bolt
4.
Hook the end
A of the locking spring into the locking lever.
– Apply Loctite 243 to bolt
4 and use it to fix the locking lever. Make
sure that the other end of the locking spring rests against the housing
bracket
B.
– Insert the ratchet carrier
5 into the gear shifting gate as shown in the
illustration.
– Use a small quantity of grease to fix the collar bushing
6 on the
ratchet carrier.
–Mount the ratchet carrier together with the gear shifting gate in the
housing. The ratchets 7 must be slightly squeezed to insert the
ratchet carrier into the locking drum.
– Fix the gear shifting gate with 3 bolts
8 on the housing.
6-4C
1
2
3
4
A
B
5
6
7
7
8