Preassembling The Shift Shaft; Checking The Clutch - KTM 450 XC 2008 Repair Manual

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30/ENGINE - WORK ON INDIVIDUAL PARTS

Preassembling the shift shaft

19.31
5
0 0 5
0 0 1
1
0 0 2
2

Checking the clutch

19.32
LOCTITE 243
Check clutch facing discs 
»
If there is discoloration or scoring:
Change all clutch facing discs.
Check the thickness of clutch facing discs 
Clutch facing disc - thickness
»
If the clutch facing disc does not meet specifications:
Change all clutch facing discs.
Check clutch disks 
and 
»
If the clutch discs are not level and have pittings:
Change all clutch discs.
Check needle bearing 
»
If there is damage or wear:
Change the needle bearing.
Check the contact surfaces of the clutch facing discs in outer clutch hub 
»
If the contact surface is very worn:
Change the clutch facing discs and the outer clutch hub.
Fix the short end of the shift shaft in a vise.
Specification
Use soft jaws.
Mount sliding plate 
3
0 0 3
4
0 0 4
to the shift quadrant.
Mount pressure spring 
Push on spring guide 
6
0 0 6
end facing upward and lift the offset end over abutment bolt 
200175-01
Mount stop disk 
9
bk
8 7
bl
for discoloration and scoring.
.
for damage and wear.
for damage and wear.
with the guide pin facing downward and attach the guide pin
.
, push return spring 
.
2
3
LOCTITE 243
2
6
5
> 1.90 mm (> 0.0748 in)
for wear.
over the spring guide with the offset
.
1
4
118
600286-01

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525 xc 2008

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