Assembly Countershaft - KTM 85 SX 2004 Repair Manual

5-13
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
12
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
11
– Easy operation of gear-change
– Check the friction bearings in the idler gears for score marks and a
Carefully clean components and replace damaged components.
10
NOTE:
– Always place circlips with sharp edge facing the components secured,
9
– Check that after any repair of the transmission, circlips should axially
– Apply graphite paste (MOS2) to the idler gears before you mount
8
7
6

Assembly countershaft

– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Slide on the 2nd idler gear
– Mount the circlip
– Slip on the 6th sliding gear
5
– Slip on the 3rd idler gear
– Mount the circlip
– Mount the 5th sliding gear
4
– Slip on the stop disk
– Slide on the 1st gear idler
– Finally, check all of the gears for smooth operation.
3
2
1
gears
flawless condition.
ensuring that they are not overexpanded (use special pliers).
not move more than 0.20 mm and must not seize between stop discs.
them.
1
2
(21 SW) with the sharp edge facing up.
4
mount the circlip (21 SW).
5
6
gear with the collar facing down.
7
(21 SW) with the sharp edge facing up.
8
9
(15x25x0.5) and the needle bearing
bl
facing down and slip on the stop disk
with the collar facing down.
3 with the shift groove facing up and
with the collar facing up and the 4th idler
with the shift groove facing down.
with the notches in the contact surface
bm
(15x25x1).
bk
.