Shift Mechanism – Checking Parts For Wear; Preassembling The Shift Shaft - KTM 2003 950 Adventure Repair Manual

1
1
3
3
6
5
B
7
8
bk
1
2
8
7
9
4
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Preassembling the shift shaft

– Mount the shift rail on the shift shaft by engaging the guide bolt
– Attach the spring
5
NOTE: the noses on the plastic sleeve will engage in the opening in the
shift rail and the shift shaft and hold the spring in place.
9
– Mount the return spring
shift quadrant.
– Slide the disk
A
Shift mechanism – checking parts for wear
Shift forks
1
Check the leaf for wear.
Check the driving bolt for the shift drum for wear.
2
Shift rolls
3
Check the shift rolls for hair cracks and pressure marks. It
should be easy to turn the shift rolls on the driving bolts
of the shift forks.
Shift drum
4
Check the shift grooves for wear.
Check both grooved ball bearings in the shift drum for
wear.
Shift rail
5
Check for wear at the points of contact.
Check the return surface
(replace if excessively grooved).
Guide bolts
6
Check for a tight fit and wear.
Guidance
Check play (play between guide bolts and slider
max. 0.7 mm).
and slide on the plastic sleeve
7
such that the offset
9
onto the shift shaft.
bk
5-16
on the shift rail for wear
B
6
.
8
runs towards the
A
2
.