KTM 200 - Primary Drive and Clutch Assembly

–Grease the shaft seal ring of the shift shaft.
– Oil the shift shaft and insert it into the housing. Do not forget the
stop disc! When mounting the shift shaft make sure that both legs of
the return spring rest against the prolongation of the shift rail
1.
Kickstarter
–Grease the bearing bore of the kickstarter shaft in the housing.
– Insert the preassembled kickstarter shaft into the housing so that the
locking pawl is located on the kickstarter shaft behind the release
plate in the housing.
–Pretension the kickstarter spring clockwise and hook it into the
corresponding bore in the housing
A.
Primary drive, clutch
–Grease the shaft seal ring of the crankshaft.
– Put the oiled O-ring (25x2 mm) onto the crankshaft and mount the
distance bushing with the chamfer facing the crank web so that the
O-ring is located in the chamfer.
– Insert the woodruff key into the crankshaft.
– Put the primary gear onto the crankshaft with the collar facing the
housing.
– Mount a new detent edged ring and a hexagon nut (LH thread).
– Mount the holding spanner for the primary gear and tighten the
hexagon nut with 180 Nm (133 ft.lb.).
– Put the stop disc (17.2x26x1 mm) and the intermediate starter gear
2 onto the countershaft.
– Oil the bearing of the outer clutch hub
3 and put it onto the main
shaft.
6-5C
A
2
1
3