KTM 250 SX 2003 Owner's Handbook Manual page 90

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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
gears
– Easy operation of gear-change
Carefully clean components and replace damaged components.
NOTE: Always place circlips with sharp edge facing the components
secured, 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 (0.006 in) and must not seize between stop
discs.
Assembly countershaft
– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Mount the split needle bearing
2
idler gear over the bearing with the collar facing down.
– Mount the internally toothed stop disk
4
(25x1.64) with the sharp edge facing up.
– Mount the 4th sliding gear
mount circlip 6 (25x1.64) and stop disk
– Slide on the split needle bearing
– Mount the internally toothed stop disk
bearing and mount circlip
bm
– Mount sliding gear 5
bo
mount needle bearing
– Slide on the 1st idler gear
bq
stop disk (17.2x30x1).
– Finally check all gears for easy running.
1
on the main shaft and slide the 2nd
3
(25.2x32x1 mm) and circlip
5
with the shift groove facing down,
7 (25.2x32x1.5).
8
with the 3rd idler gear
bk
(25.2x32x1.5) over the
bl
(25x1.64).
bn
, slide on the stop disk
.
bp
with the shift groove facing down and
9
.
(20x32x1) and