General Information On Servicing The Transmission; Main Shaft - KTM 450 SX-F Repair Manual

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General information on servicing the transmission

Clamp the main shaft or countershaft in the vise (use protective jaws).
If continuing to use the shift ring and fixed gears, mark the installed position.
Remove the gears and check the following parts for damage and wear:
– Bearings
– Main shaft and countershaft bearing positions and idler shaft bearing positions
– Shift dogs on the gears
– Tooth faces on all gears
– Tooth profiles on the main shaft and countershaft as well as the corresponding gear wheels
– Check the shift rings for smooth operation in profile
– Insert the pushrod for clutch control in the main shaft and check for clearance and
wear at the guide bushing
Carefully clean all parts and replace if damaged.
Always use new lock rings when you repair the transmission.
Do not overstretch the lock rings when mounting.

Main shaft

– Clamp the main shaft in a vise with the toothed end facing down (use protective jaws).
– Carefully oil all parts before mounting.
– Mount the distance sleeve
– Mount the 4 th gear fixed gear
– Mount the distance ring
4
– Mount the 3 rd gear fixed gear
– Mount the distance sleeve
– Mount the 2 nd gear fixed gear
– Mount the stop disk (31x17x1mm).
7
1
2
.
1
.
2
to match the installed position mark.
3
(25x29x2.4mm).
to match the installed position mark.
5
.
2
to match the installed position mark.
6
3
4
5
2
6
7