Assembling The Counter Shaft - KTM 400-660 LC4 1998-2005 Repair Manual

5-22E
Important note regards working on transmission
16
– Fix the main shaft or countershaft, respectively, in the vise (use
– Clean and check all parts.
15 Always use new lock washers when performing repair work on the
transmission !
Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
14
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
Check the pivot points of the transmission shafts.
13
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
Check the needle bearings of the idler gears.
12
11

Assembling the counter shaft

10
– Mount counter shaft in vise with collar facing downwards.
– Oil and mount needle cage
– Slide 2nd gear
– Mount stop disc
9
– Mount 5th gear
– Fit circlip
– Mount needle cage
– Mount stop disc
8
– Fit 3rd gear
7
– Mount needle cage
6
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
Check all gears for smooth operation.
5
4
3
2
1
special vise jaws to avoid damaging of the shafts) and remove the
gear wheels.
2
over needle cage with collar facing downwards.
3
(22.7x32.0x1.50 mm) with clearance towards
4
gear wheel and circlip with sharp edge facing upwards.
5
with shift groove facing upwards.
6 with sharp edge down and stop disc
mm).
8
and fit 4th gear
bk
(22.7x32.0x1.50 mm) and circlip
edge facing up.
bm
with shift groove down and mount stop disc
bn
(22.2x35.0x1.50 mm) .
bo
, 1st gear
bq
disc (20.2x35.0x1.0 mm)
1
.
7 (22.7x32.0x1.50
9
with shift dogs facing up.
bl
bp
with collar facing up and fit stop
.
with sharp