Aligning The Return Spring - KTM 2003 950 Adventure Repair Manual

1
4
5
6
B
Shift mechanism
– Mount the locking lever
M5x20 bolt and tighten to 6 Nm.
2
– Press the locking lever down and mount the shift locating drum
NOTE: the flat parts of the shift locating drum are off center.
– Apply Loctite 243 to the M6x30 bolt
– Slide the shift shaft
from the shift locating drum and press the shift shaft towards the
case to the stop; let go of the shift rail.
3

Aligning the return spring

– Engage second or third gear.
– Check the backlash of the shift rail and the clearance of the shift
bolt.
– The backlash of the shift rail is the distance the rail travels until the
shift shaft begins to move. You should be able to feel the pressure of
the return spring. Relative to the basic position, this backlash
should be equal towards the top and towards the bottom.
– The backlash can be corrected by aligning the return spring.
– To align, dismount the shift shaft and bend the return spring as
needed at the bends
shaft. When the shift shaft is installed, the return spring must rest
against the shift bolt
support.
– Bend the return spring again if necessary.
with the spring. Apply Loctite 243 to the
1
and tighten to 10 Nm.
3
in the bearings, push the shift rail
4
using a pair of pliers. Remount the shift
B
and the dolly of the shift mechanism
6
6-6
.
2
away
5
A