Transmission; Assembly Mainshaft - KTM 85 SX 2004 Repair Manual

Transmission

Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
– Mainshaft and countershaft pivot points including idler gears
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
8
gears
– Easy operation of gear-change
– Check the friction bearings in the idler gears for score marks and a
flawless condition
7
Carefully clean components and replace damaged components.
NOTE:
– Always place circlips with sharp edge facing the components secured,
6
ensuring that they are not overexpanded (use special pliers).
– Check that after any repair of the transmission, circlips should axially
not move more than 0.20 mm and must not seize between stop discs.
– Apply graphite paste (MOS2) to the idler gears before you mount
them.
5
4

Assembly mainshaft

– Fix mainshaft in vice with toothed end upwards (use covered clamps).
– Oil all parts before assembly.
– Slide on the 5th idler gear
– Mount the circlip
– Slide on the 3rd and 4th gear sliding gear
3
facing down.
– Mount the circlip
on the 6th gear idler
– Slide on the stop disk (20.3x26x0.4)
gear
– Finally, check all of the gears for smooth operation.
2
1
1
with the shifting dogs facing up.
2
(19 SW) with the sharp edge facing up.
4 (19 SW) with the sharp edge facing up and slide
5
with the dogs facing down.
7
together with the stop disk
3
with the larger gear
6
and the mount the fixed 2nd
8
(16x26x1).
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