KTM 300 1998 - Kickstarter and Shift System Dismantling; Ignition System Component Removal

– Pulling the primary gear
1
off the crankshaft.
N OTE
: T HE PRIMARY GEAR AND THE OUTER CLUTCH HUB BELONG TOGETHER
. A LWAYS REPLACE
BOTH TOGETHER!
3.6 Kickstarter
– Remove circlip
2
and kickstarter intermediate gear.
– Carefully release collar screw
3
kickstarter spring is tensioned, release tension
on kickstarter spring and unhook spring hanger.
– Take the complete kickstarter shaft out of the housing.
– Take care of the stop disc, which stays in the housing.
!
CAUTION
!
C
AREFULLY RELEASE THE KICKSTARTER SPRING
! DANGER OF INJURY!
3.7 Shift system
– Press the sliding plate
4
back with a screw driver so it no longer engages with
the driver for the shaft roller, at the same time remove shift shaft from the housing.
N
OTE: WATCH THE STOP DISC WHICH REMAINS IN THE HOUSING.
– Remove allan head screw and take driver for roller
5
and locking piece
6
from
the shift roller.
– Disassemble locating lever
7
only if the engine case must be replaced.
– Remove allan head screw
8
and locking lever with spring.
3.8 Ignition (Kokusan)
– Undo the 5 screws and remove the ignition cover together with the gasket.
– Hold the flywheel with the holding spanner and undo the collar nut.
– Put the protection cover on the crankshaft thread, twist in the flywheel extrac-
tor and remove the flywheel.
– Undo the 3 screws and remove the stator together with the base plate.
3
2
3
4
5
6
8
7
1