Assembling The Countershaft - KTM 450 SX ATV 2010 Repair Manual

30/ENGINE - WORK ON INDIVIDUAL PARTS

Assembling the countershaft

19.47
Info
Use new lock rings with every repair.
–
Carefully lubricate all parts before assembling.
–
Check the transmission. (
0 0 b q
0 0 4
0 0 3
0 0 2
0 0 1
–
Secure the countershaft with the toothed end facing downward in the vise.
Guideline
bq
Use soft jaws
–
Mount needle bearing

4
–
Mount stop disk and lock ring

–
Mount the 5th-gear sliding gear
–
Mount lock ring and stop disk

–
Mount needle bearing
3 
–
Mount stop disk and lock ring

2
1
–
Mount the 3rd-gear sliding gear
–
Mount stop disk .

–
Mount needle bearing

–
Mount stop disk .

–
In conclusion, check all gear wheels for smooth operation.
p. 142)
0 0 b p
0 0 b n
0 0 b o
0 0 b m
0 0 b l
0 0 9
bp
bn
and 2nd-gear idler gear bo onto the countershaft with the protruding collar facing downward.

.

bm
with the shift groove facing up.
 bl
.

9
and 4th-gear idler gear with the shift dogs facing upward.

.

with the shift groove facing downward.

and 1st-gear idler gear .

0 0 b k
0 0 8
0 0 6
0 0 7
0 0 5
301262-01
bk
8
6
7
5
144