Transmission; Assembly Mainshaft - KTM EXC Repair Manual

5-15C

Transmission

Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
11
– Mainshaft and countershaft pivot points including idler gears
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
10
gears
– Easy operation of gear-change
Carefully clean components and replace damaged components.
NOTE: Always place circlips with sharp edge facing the components
9
secured, ensuring that they are not overexpanded (use special pliers).
Check that after any repair of the transmission, circlips should axially not
move more than 0.20 mm (0.006 in) and must not seize between stop
discs.
8
7
6

Assembly mainshaft

– Fix mainshaft in vice with toothed end upwards (use covered clamps).
5
– Oil all parts before assembly.
– Mount the split needle cage
over it with collar downwards.
– Place internally toothed stop disc
position and mount circlip
– Place 3
4
mount circlip
internally toothed stop disc
– Mount the split needle cage
3
downwards 2
(20.2x33x1.5 mm).
– Finally check all gears for easy running.
2
1
1
on mainshaft, push 5
4 (25x1.64 mm) with sharp edge upwards.
5
sliding gear in position with shift groove downwards,
rd
6
(25x1.64 mm) with sharp edge downwards and
7
(22.4x25.7x32.0x1.5 mm)
8
, 4
bk
gear with collar downwards and stop disc
nd
idler gear
th
3
(22.4x25.7x32.0x1.5 mm) in
9
idler gear with shift dogs
th
2
bl