Removing The Transmission Shafts; Removing The Kickstarter Shaft - KTM 400-660 LC4 1998-2005 Repair Manual

4-17E
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Removing the transmission shafts

– Pull both transmission shafts out of the bearing seats.
– Take the 3rd gear/sliding gear and the 1st gear/idler gear out of the
engine housing together with the needle bearing and the stop disc.
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.

Removing the kickstarter shaft

– Put kickstarter onto kickstarter shaft and hold in this position.
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– Unscrew stop bolt and relieve starter spring tension by releasing
the kickstarter.
– Remove kickstarter shaft assembly from housing.
– Take the starter gear out of the housing bag together with the
needle bearing and the stop discs.
– Clean all parts and check for wear, replace if necessary.
NOTE: When an engine is completely overhauled it is recommended
that all gaskets, shaft seal rings, O-rings and, possibly, all bearings are
renewed.