Preassembling The Shift Shaft; Disassembling The Main Shaft - KTM 400 EXC AUS 2011 Repair Manual

30JENGINE - WORK ON THE INDIVIDUAL PARTS
137
400372-11
PI'Ilsslmbllnl thl shift shift
~ o
~~.f)
~ ~
CD
200175-01
Disuslmblinl tha lIIIin shift
»
If the sliding plate is worn,
- Change the sliding plate.
- Check return surface. on the sliding plate for wear.
:. If there is marked indentation:
- Change the sliding plate.
- Check guide bolts. for firm seating and wear.
:. If the guide bolts are loose or worn:
- Change the sliding plate.
- Preassemble the shift shaft. (.- p. 137)
- Check clearance. between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.4 ... 0.8 mm (0.016 ... 0.031 in)
quadrant
»
If the measured value does not meet specifications,
- Change the sliding plate.
- Secure the short end of the shift shaft in the bench vise.
Guideline
I
Use soft jaws.
- Mount sliding plate. with the guide pin facing downward and put the guide pin
on the shift quadrant.
- Mount pressure spring •.
- Slide on spring guide., push return spring
e,
with the offset end facing upward,
over the spring guide and lift the offset end over abutment bolt •.
- Mount stop disk •.
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
I
Use soft jaws.
- Remove stop disk. and 2nd-gear fixed gear •.
- Remove 6th gear idler gear •.
- Remove split needle bearing. and stop disk •.
- Remove lock ring •.
-
Remove 3rd/4th gear sliding gear •.
- Remove lock ring •.
- Remove stop disk. and 5th gear idler gear •.
- Remove split needle bearing •.
I
30JENGINE - WORK ON THE INDIVIDUAL PARTS
137
400372-11
PI'Ilsslmbllnl thl shift shift
~ o
~~.f)
~ ~
CD
200175-01
Disuslmblinl tha lIIIin shift
»
If the sliding plate is worn,
- Change the sliding plate.
- Check return surface. on the sliding plate for wear.
:. If there is marked indentation:
- Change the sliding plate.
- Check guide bolts. for firm seating and wear.
:. If the guide bolts are loose or worn:
- Change the sliding plate.
- Preassemble the shift shaft. (.- p. 137)
- Check clearance. between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.4 ... 0.8 mm (0.016 ... 0.031 in)
quadrant
»
If the measured value does not meet specifications,
- Change the sliding plate.
- Secure the short end of the shift shaft in the bench vise.
Guideline
I
Use soft jaws.
- Mount sliding plate. with the guide pin facing downward and put the guide pin
on the shift quadrant.
- Mount pressure spring •.
- Slide on spring guide., push return spring
e,
with the offset end facing upward,
over the spring guide and lift the offset end over abutment bolt •.
- Mount stop disk •.
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
I
Use soft jaws.
- Remove stop disk. and 2nd-gear fixed gear •.
- Remove 6th gear idler gear •.
- Remove split needle bearing. and stop disk •.
- Remove lock ring •.
-
Remove 3rd/4th gear sliding gear •.
- Remove lock ring •.
- Remove stop disk. and 5th gear idler gear •.
- Remove split needle bearing •.
I