General Information On Servicing The Transmission; Assembling The Main Shaft - KTM 2003 950 Adventure Repair Manual

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General information on servicing the transmission

– Clamp the main shaft in the vise (use protective jaws) and remove
the gears.
– Clean and check all parts.
Use new lock rings whenever you repair the transmission.
Check the tooth profile on the transmission shafts and sliding gears for
wear.
Place the sliding gears on the transmission shafts and check whether
they run smoothly on the teeth.
Check the bearing positions on the transmission shafts.
Mount the idler gear with bearings on the transmission shaft and check
for clearance.
Check the needle bearings in the idler gears.

Assembling the main shaft

– Clamp the main shaft in the vise (use protective jaws) with the gear
facing down.
– Mount the needle bearing
needle bearing with the claws pointing up.
– Mount the stop disk (28.3 x 35.75 x 1.5 mm) and the lock ring
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with the sharp edge facing up.
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– Mount the 3rd and 4th gear sliding gear
outer diameter) facing down.
– Mount the stop disk (22.2 x 30,2 x 1.5 mm).
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– Slip on the needle bearing
needle bearing with the claws pointing down.
– Slip on the 2nd gear fixed gear
mount the stop disk (20.2 x 28 x 1.5 mm).
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Check all gear wheels for smooth operation.
and slide the 5th gear idler
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with 4th gear (larger
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and slide the 6th gear idler
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with the collar facing down and
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over the
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over the
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