KTM 300 1998 - Clutch System Service; Primary Drive Removal

– Cover the crankcase.
– Place piston on wooden jig and remove both piston pin locking pins.
– Expel piston pin from piston without exerting undue force. Use a suitable mand-
rel if necessary.
– Remove piston and piston pin needle-bearing from conrod eye.
– Remove the cylinder base gasketS.
3.3 Clutch cover
– Remove collar screws and clutch cover including gasket.
N
OTE: T
HE WATER PUMP COVER
1
, THE OUTER COVER
2
AND THE COVER LID
3
DO NOT
NEED TO BE REMOVED
. THE WATER PUMP AND THE CENTRIFUGAL TIMER REMAIN IN THE
CLUTCH COVER
.
3.4 Clutch discs
– Loosen collar screws in diagonally opposite sequence to prevent wedging of discs
as springs expand.
– Remove collar screws, springs and spring retainer.
– Remove the pressure cap and pull out the clutch push rod together with the
thrust bearing.
– Take the disc package out of the outer clutch hub.
3.5 Primary drive
– Block the primary gear with the gear wheel segment
4
(see illustration).
–
Undo the hexagon nut (LH thread) and remove it together with the detent edged ring.
– Release the lock washer of the inner clutch hub.
– Connect clutch holder
5
to inner clutch hub and loosen hexagon nut (see illu-
stration).
– Remove clutch holder.
– Remove inner clutch hub and outer clutch hub together with bearing from main
shaft.
3
3
1
2
3
4
5