Checking Shift Mechanism - KTM 400 EXC AUS 2011 Repair Manual

30JENGINE - WORK ON THE INDIVIDUAL PARTS
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- Check needle bearing. and collar sleeve. for damage and wear.
~
If there is damage or wear:
- Change the needle bearing and collar sleeve.
- Check the intermediate clutch discs. for damage and wear.
»
If the intermediate discs are not flat or have punctiform outbreaks:
- Change all intermediate discs.
- Check clutch facing discs. for discoloration and scoring.
»
If there is discoloration or scoring:
- Change all clutch lining discs.
- Check the thickness of clutch facing discs •.
Clutch facing disc - thickness
Outer
I
2.6 ... 2.7 mm (0.102 ... 0.106 in)
Innermost
I
2.9 ... 3.0 mm (0.114 ... 0.118 in)
• If the clutch lining disc does not meet specifications:
- Change all clutch lining discs.
- Check pretention ring and support ring" for damage and wear.
»
If there is damage or wear:
- Change the pretension ring and support ring.
- Check the inner clutch hub. for damage and wear.
»
If there is damage or wear:
- Change the inner clutch hub.
Check shift forks
0
for wear on blade •.
Shift fork
Thickness at leaf
14.85 ... 4.95 mm (0.1909 ...
0.1949 in)
• If the measured value does not meet specifications:
-
Change the shift fork.
-
Check shift grooves. of shift drum. for wear.
•
If the shift groove is worn:
-
Change the shift drum.
-
Check the seat of the shift drum in grooved ball bearing •.
•
If the shift drum is not correctly seated:
-
Change the shift drum andlor the grooved ball bearing.
-
Check grooved ball bearing. for smooth operation and wear.
• If the grooved ball bearing does not move easily or is worn:
-
Change the grooved ball bearing.
-
Check shift rollers
0
for surface damage and cracking.
•
If the shift roller exhibits surface damage or cracking:
- Change the shift roller.
- Check springs. of the shift rails for damage and wear.
• If the spring is damaged or worn:
- Change the spring of the shift rail.
- Check shift rails. for run-out on a lever surface.
»
If there is run-out:
- Change the shift rail.
- Check the shift rails for grooving, scoring and smooth operation in the shift fork.
• If the shift rail has grooving, scoring or does not move easily in the shift fork:
- Change the shift rail.
- Check sliding plate. for wear on contact
areas •.
I
30JENGINE - WORK ON THE INDIVIDUAL PARTS
136
Chlckl!lllhift mlchanlsm
~ /.
.-r:!ZJ~
""@ , . ' .
@~~O
II/@~ ~
e.
,%;{'O ....
8 --0 ~
(I
'.
'.~\
°rtiftt-·
~
ij
I
e-
CD-,
. O 8-~
~ ~e
~
--e
Cit
200174-01
- Check needle bearing. and collar sleeve. for damage and wear.
~
If there is damage or wear:
- Change the needle bearing and collar sleeve.
- Check the intermediate clutch discs. for damage and wear.
»
If the intermediate discs are not flat or have punctiform outbreaks:
- Change all intermediate discs.
- Check clutch facing discs. for discoloration and scoring.
»
If there is discoloration or scoring:
- Change all clutch lining discs.
- Check the thickness of clutch facing discs •.
Clutch facing disc - thickness
Outer
I
2.6 ... 2.7 mm (0.102 ... 0.106 in)
Innermost
I
2.9 ... 3.0 mm (0.114 ... 0.118 in)
• If the clutch lining disc does not meet specifications:
- Change all clutch lining discs.
- Check pretention ring and support ring" for damage and wear.
»
If there is damage or wear:
- Change the pretension ring and support ring.
- Check the inner clutch hub. for damage and wear.
»
If there is damage or wear:
- Change the inner clutch hub.
Check shift forks
0
for wear on blade •.
Shift fork
Thickness at leaf
14.85 ... 4.95 mm (0.1909 ...
0.1949 in)
• If the measured value does not meet specifications:
-
Change the shift fork.
-
Check shift grooves. of shift drum. for wear.
•
If the shift groove is worn:
-
Change the shift drum.
-
Check the seat of the shift drum in grooved ball bearing •.
•
If the shift drum is not correctly seated:
-
Change the shift drum andlor the grooved ball bearing.
-
Check grooved ball bearing. for smooth operation and wear.
• If the grooved ball bearing does not move easily or is worn:
-
Change the grooved ball bearing.
-
Check shift rollers
0
for surface damage and cracking.
•
If the shift roller exhibits surface damage or cracking:
- Change the shift roller.
- Check springs. of the shift rails for damage and wear.
• If the spring is damaged or worn:
- Change the spring of the shift rail.
- Check shift rails. for run-out on a lever surface.
»
If there is run-out:
- Change the shift rail.
- Check the shift rails for grooving, scoring and smooth operation in the shift fork.
• If the shift rail has grooving, scoring or does not move easily in the shift fork:
- Change the shift rail.
- Check sliding plate. for wear on contact
areas •.
I