Important Note Regards Working On Transmission; Assembling The Main Shaft - KTM 400-660 LC4 1998-2005 Repair Manual

Important note regards working on transmission

– Fix the main shaft or countershaft, respectively, in the vise (use
special vise jaws to avoid damaging of the shafts) and remove the
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gear wheels.
– Clean and check all parts.
Always use new lock washers when performing repair work on the
transmission !
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Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
9
Check the pivot points of the transmission shafts.
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
Check the needle bearings of the idler gears.
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7

Assembling the main shaft

– Mount the main shaft in a vise with the gearwheel facing
6
downwards (use protective jaws).
– Mount the needle cage
dogs facing upwards.
– Mount stop disc
sharp edge facing up.
5
– Mount 4th gear
– Secure it with the circlip
the stop disc
– Mount needle cage
– Mount 2nd gear
NOTE: Check all gears for smooth operation.
4
3
2
1
1
and slide the 3rd gear
3
(22.7x32x1.5 mm) and the circlip
5
with the shift groove facing down.
6
with the sharp edge down and mount
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(22.7x32x1.5 mm).
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and 5th gear with the shift dogs down.
bk bl
and stop disc (20.2x35x1 mm).
5-21E
2
with the shift
4
with the