Preassembling The Shift Shaft (200 Duke); Disassembling The Main Shaft; Duke) - KTM 125 DUKE EU Repair Manual

16 ENGINE

16.4.49 Preassembling the shift shaft (200 Duke)

16.4.50 Disassembling the main shaft (200 Duke)
–
Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
–
Remove stop disk and 2nd-gear fixed gear
1
–
Remove the 5th-gear idler gear
–
Remove stop disk .
4
–
Remove lock ring .
5
–
Remove 3rd/4th-gear sliding gear
–
Remove lock ring .
7
–
Remove stop disk .
8
–
Remove collar bushing
–
Remove 6th-gear idler gear
–
Remove stop disk .
bl
–
Preassemble the shift shaft. (
–
Check the play
Shift shaft – play in sliding plate/shift
quadrant
»
304514-10
–
Fix the short end of the shift shaft in a vise.
Guideline
Use soft jaws.
–
Mount sliding plate
the shift quadrant.
–
Mount preload spring
–
Push on spring guide
end facing upward and lift the offset end over abutment bolt
304512-10
–
Mount washer
.
2
.
3
.
6
.
9
.
bk
between the sliding plate and the shift quadrant.
F
If the measured value does not equal the specified value:
–
Change the shift shaft.
with the guide pin facing down and attach the guide pin to
1
.
2
, push return spring
3
.
6
305899-10
p. 151)
0.15... 0.45 mm (0.0059...
0.0177 in)
over the spring guide with the offset
4
151
.
5