KTM 200 - Engine Housing Assembly

Assembling the engine housing
– Remove the engine holder at the mounting rack.
– Make sure that both dowels are properly located in the right housing half.
– Slightly grease the sealing surface of the housing and mount a new gasket.
– Make sure that the rubber is properly inserted into the left housing half and that the sleeves have not slipped off the driving pins
of the shift forks.
–Grease the shaft seal rings of the left housing half and put on the left housing half.
– Check the housing gasket for proper fit.
–Grease the threaded sections and the contact surfaces at the heads of the housing bolts. Insert the bolts and assemble the hou-
sing (bolt lengths are indicated in the illustration).
– Before and after tightening the housing bolts with 8 Nm (6 ft.lb.) check all shafts for easy operation.
– Fix the engine on the mounting rack.
– Cut the protruding gasket off cleanly at the sealing surfaces at cylinder base and reed valve housing.
6-3C
M6x... mm
50
50
50
50
50
55
55
50
55
55
55
Engine sprocket
– Oil the O-ring (≠ 1.78 mm) and put it on the countershaft.
– Mount the distance bushing
1 in such a way that the O-ring is
located in the chamfer.
– Put the chain sprocket onto the countershaft with the collar facing
inwards and fix it with the circlip (sharp edge outwards).
–Tap the chain sprocket with a hollow mandrel or a similar tool to
slightly pretension the O-ring and to press the circlip into the groove.
Ignition system
– Insert the woodruff key into the crankshaft.
– Apply Loctite 243 to the thread of the bolt and fix the stator in the
housing with the 3 bolts without yet tightening the bolts.
–Turn the stator so that mark of the stator coincides with the middle
mark of the housing. Then tighten all three bolts of the stator.
NOTE: The left-hand mark
A in the housing is intended for the 2K-1 and
2K-2 ignition systems. The right-hand mark
B in the housing is meant for
the 2K-3 ignition system.
– Insert the cable guide into the housing.
1
A
B