User's Manual

5-4E

Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028 -E

Working on the clutch cover

NOTE: dismantling the clutch cover is neccessary if parts are damaged

or the O-ring is leaking.

– Turn kickstarter shaft

1 counter-clockwise and remove ratchet gear

2. Check gearing for wear.

NOTE: If the kickstarter shaft is to be removed, the outer circlip must

be removed, carefully pulling the kickstarter shaft out of the cover.

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WARNING

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HE KICKSTARTER SPRING IS PRETENSIONED. IT MUST BE STRESS-RELIEVED WHEN

THE KICKSTARTER SHAFT IS PULLED OUT

– Clean kickstarter shaft and renew O-ring

3 (up to the 2003 model).

NOTE:

– make shure that the O-ring is mounted in the second groove

– starting with the 2004 model, a shaft seal ring

5 is installed in the

engine instead of an O-ring and the kickstarter shaft no longer has a

second groove. Pry out the old shaft seal ring and press the new

shaft seal ring in until flush with a suitable tool.

During assembly only push the kickstarter shaft into the clutch cover far

enough to be able to reinsert the spring (

6 and 7). The spring is

pretensioned by turning the kickstarter shaft in a counter-clockwise

direction, then completely push the kickstarter shaft into the clutch

cover. Hold the kickstarter shaft turned, mount the ratchet gear and

release the kickstarter shaft again.

NOTE: the end of the kickstarter shaft gearing has a deformation

8 to

prevent the kickstarter shaft from hitting against the clutch cover,

causing it to wedge with the gearing of the ratchet gear. Make sure to

keep a gap between the kickstarter shaft and stop