hi guy thought this might help anyone replaceing the cush drive rubbers on the sd.
first thing take off wheel and remove rear sprocket.
tools required are
drill
drill bit( about 6/7mm
carbide metel burr bit again 6/7mm
hammer
27mm socket
long punch( 3/8 drive extension
first drill hole in rubber making sure you don,t drill through casting at rear off rubber
then using burr carefully grind away outer case of bush

then hammer out from the rear with long extension(punch)
when putting new bush in smear with grease
then using a 27mm socket press back in using a hammer
make sure you don,t push it in to far, they should be flush with the counter sink.
give the wheel a clean and job done
once i knew what i was doing it only took me 10mins per bush

klink the most damage was a small mark on the inside
all you need to do is take it easy with the burr. when you buff through the metal of the bush you can see the difference in the metal texture to the wheel

Shop manual says:
"To check the jerk damper: hold the rear wheel while you try to move
the rear sprocket back and forth in the running direction.
NOTE: the transmission should be switched to neutral.
Maximum clearance: 5 mm (measured on the outside of the rear
sprocket)."

It also says: "To replace, see Owner's Manual." Of course the owners manual just says to check them, not how to replace them. Funny KTM playing tricks like that.

p.s. scotsduke, you forgot to powdercoat your wheels a bright colour before you put the new rubbers in!

Great thread.

These things are what makes this forum invaluable.

Just checked mine and I have play between the wheel and the sprocket.

I presume there should be no free play at all?

Also.
can somebody recommend a dealer in the UK that might have the bushes in stock?

This is a really useful thread.