Assembling The Main Shaft; Disassembling The Countershaft - KTM 400 EXC AUS 2011 Repair Manual

30JENGINE - WORK ON THE INDIVIDUAL PARTS
138
Aulmbllnl thl IIIIln shaft
• Info
I
Use new lock rings with every repair.
- Carefully lubricate all parts before assembling.
- Check the transmission. ( .. p. 139)
Il,
g@
200178-01
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
I
Use soft jaws
-
Mount split needle bearing., attach 5th gear idler gear. with shift dog facing upward.
- Mount stop disk. and lock ring
e.
- Attach 3rd/4th gear sliding gear. with the small toothed wheel facing downward and mount lock ring •.
- Attach stop disk. and split needle bearing •.
- Attach 6th gear idler gear. with the shift dog facing downward.
- Attach 2nd gear fixed gear. with the collar facing downward and stop disk •.
- Finally, check all gear wheels for smooth operation.
Diaaalmblini thl countll1lhaft
I
200179-01
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
I
Use soft jaws
- Remove stop disk. and 1st-gear idler gear •.
- Remove needle bearing. and stop disk
e.
-
Remove 5th gear sliding gear. and lock ring •.
-
Remove stop disk. and 3rd gear idler gear •.
- Remove needle bearing. and 4th gear idler gear •.
- Remove needle bearing. and stop
disk •.
- Remove lock ring. and 6th gear sliding gear •.
- Remove stop disk. and lock ring •.
- Remove 2nd gear idler gear. and needle bearing •.
30JENGINE - WORK ON THE INDIVIDUAL PARTS
138
Aulmbllnl thl IIIIln shaft
• Info
I
Use new lock rings with every repair.
- Carefully lubricate all parts before assembling.
- Check the transmission. ( .. p. 139)
Il,
g@
200178-01
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
I
Use soft jaws
-
Mount split needle bearing., attach 5th gear idler gear. with shift dog facing upward.
- Mount stop disk. and lock ring
e.
- Attach 3rd/4th gear sliding gear. with the small toothed wheel facing downward and mount lock ring •.
- Attach stop disk. and split needle bearing •.
- Attach 6th gear idler gear. with the shift dog facing downward.
- Attach 2nd gear fixed gear. with the collar facing downward and stop disk •.
- Finally, check all gear wheels for smooth operation.
Diaaalmblini thl countll1lhaft
I
200179-01
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
I
Use soft jaws
- Remove stop disk. and 1st-gear idler gear •.
- Remove needle bearing. and stop disk
e.
-
Remove 5th gear sliding gear. and lock ring •.
-
Remove stop disk. and 3rd gear idler gear •.
- Remove needle bearing. and 4th gear idler gear •.
- Remove needle bearing. and stop
disk •.
- Remove lock ring. and 6th gear sliding gear •.
- Remove stop disk. and lock ring •.
- Remove 2nd gear idler gear. and needle bearing •.