KTM 250 SX - Manual (Page 52)

5-15C
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 mainshaft
– Fix mainshaft in vice with toothed end upwards (use covered clamps).
– Oil all parts before assembly.
– Mount the split needle cage
1 on mainshaft, push 5 th idler gear 2
over it with collar downwards.
– Place internally toothed stop disc 3 (22.4x25.7x32.0x1.5 mm) in
position and mount circlip 4 (25x1.64 mm) with sharp edge upwards.
– Place 3 rd sliding gear 5 in position with shift groove downwards,
mount circlip 6 (25x1.64 mm) with sharp edge downwards and
internally toothed stop disc 7 (22.4x25.7x32.0x1.5 mm)
– Mount the split needle cage 8 , 4 th idler gear 9 with shift dogs
downwards 2 nd gear bk with collar downwards and stop disc bl
(20.2x33x1.5 mm).
– Finally check all gears for easy running.
1
5
6
7
8
9
10
11
2
3
4