Assembling The Countershaft - KTM 2003 950 Adventure Repair Manual

bs
br
bq
bp
bo
bn
bm
bl
bk
General information on servicing the transmission
– Clamp the main shaft or countershaft in the vise (use protective
– 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. Mount the bearing ring
using a suitable tube.

Assembling the countershaft

– Clamp the countershaft in the vise (use protective jaws) with the
9
– Oil the needle bearing
8
– Slide the 2nd gear idler
– Mount the stop disk
7
– Mount the 6th gear sliding gear
5
6
– Mount the lock ring
– Mount the needle bearing
– Slip on the 4th gear idler
4
– Mount the stop disk
3
– Mount the 5th gear sliding gear
– Mount the 1st gear idler
2
1
Check all gear wheels for smooth operation.
jaws) and remove the gears. Pull off the bearing ring.
collar facing down.
and mount.
1
with the groove facing up over the needle
2
bearing.
(30.2 x 39 x 1.5 mm) and the lock ring
3
with the sharp edge facing up.
with the sharp edge facing down and the stop
6
disk (26.2 x 36 x 1.5 mm).
7
8
over the needle bearing with the collar facing up.
bl
(26.2 x 36 x 1.5 mm) and lock ring
bm
the sharp edge facing up.
and the stop disk (24.3 x 35.75 x 1.0 mm).
bp
bq
bearing and the stop disk
br
with the shift groove facing up.
5
and and slide the 3rd gear idler
9
with the collar facing down.
with the shift groove facing down
bo
with the groove facing down, the needle
(20.2 x 34 x 1.0 mm).
bs
5-18
4
bk
with
bn