Mounting The Kickstarter Unit; Mounting Transmission And Shift Mechanism - KTM 400-660 LC4 1998-2005 Repair Manual

1
3
4
– Place left-hand housing half in engine work stand.

Mounting the kickstarter unit

– Insert stop disc (22.2x35x2 mm), starter gear
2
– Insert the pre-assembled kickstarter shaft into the bearing seat,
A

Mounting transmission and shift mechanism

– Insert stop disc (20.2x35x1 mm), 1st gear wheel
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
– Mount transmission shafts together and slightly turn them.
– Grease the driving pins of the shift forks and mount the shift rollers
– Hook shift fork with legs of same length in the sliding gear of the
– Fit the other two shift forks into the gears of the counter shaft,
U
SED SHIFT FORKS SHOULD BE MOUNTED IN THE SAME SLIDING GEAR AS BEFORE
2
stop disc (22.2x30x1.5 mm) into housing.
putting it through the starter gear. Make sure that the starter spring
A
slips into opening of the housing.
down into the housing and the needle bearing into the idler gear.
main shaft.
paying attention to the marks applied during disassembly.
!
CAUTION
6-2E
1
, needle bearing and
3
with collar facing
4
.
!
.