Assembly Countershaft - KTM EXC Repair Manual

Transmission
Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
13
– 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
12
– Easy operation of gear-change
Carefully clean components and replace damaged components.
NOTE: Always place circlips with sharp edge facing the components
11
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
10 discs.
9

Assembly countershaft

– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Push stop disc
– Mount 3
– Mount 5
– Remove countershaft from vice and fix again with toothed end
– Mount 4
1
– Finally check all gears for easy running.
2
3
4
5
6
7
8
gears
1
(26x40x1,5 mm) onto countershaft.
2
idler gear with shift dog recesses upwards and circlip
rd
(25x2 mm) with sharp edge upwards.
sliding gear 4 with shift groove downwards, stop disc
th
(22,2x33x1,5 mm), needle cage
recesses downwards and stop disc
upwards on the countershaft.
upwards.
9
sliding gear
th
(28,2x40x1,5 mm), needle cage
recesses downwards and stop disc
6 7
, 1 free gear with shift dog
st
8
(17,2x34x1,5 mm) with collar
with shift dog upwards, stop disc
bl bm
, 2 idler gear with shift dog
nd
bn
(25,7x40x1,5 mm).
5-16C
3
5
bk