KTM 250 SX 2003 Owner's Handbook Manual page 87

LOCTITE 243
3
0,40 -
0,80 mm
9
5
E
4
D
6
C
LOCTITE 243
1
A
LOCTITE 243
2
3
1
Shift mechanism
Shift forks
Check shift fork blades
Shift roller
Check shift grooves for wear.
Check position of shift roller in grooved ball bearings
Slide plate
Check slide plate at meshing points
Check return surface
Check that guide pin
Sliding guides
Check sliding guides (excess between guide pin and shift quadrant not
to be more than 0.7 mm / 0.03 in).
Grooved ball bearings
Check grooved ball bearings for easy movement.
Shift mechanism
Assemble shift mechanism (see below) and check free play between slide
plate
(0.016 - 0.032 in).
Preassembly of shift shaft
– Fix shift shaft in vice at shorter end (use covered clamps).
– Mount slide plate
into shift quadrant
– Mount pressure spring
– Slide on spring guide
upwards over the spring guide and lift offset end over bolt
illustration).
– Mount the stop disc
7
10
8
1
B
1
A
and shift roller driving pin
2
4
D
for wear (renew, if strongly notched).
E
is securely fixed and check for wear.
3
4 5
and shift quadrant . Free play should be 0.40 - 0.80 mm
4
with guide pins downwards, hook guide pins
5
.
6
.
7
, slide on return spring
bk
(14x30x1 mm).
LOCTITE 243
B
for signs of wear.
3
.
C
for wear.
8
with offset end
4-12
9
(see