KTM 2008 450 XC ATV, Repair Manual

Page: 126 / 223

0 0 4 4
0 0 bn bn
0 0 5 5
0 0 2 2
0 0 bp bp
0 0 cl cl
0 0 3 3
0 0 bo bo
0 0 ck ck
0 0 9 9
0 0 bk bk
0 0 6 6
0 0 bl bl
0 0 bs bs
0 0 bt bt
0 0 cm cm
0 0 1 1
0 0 7 7
0 0 br br
0 0 8 8
0 0 bq bq
0 0 bm bm
30/ENGINE - WORK ON INDIVIDUAL PARTS
124
–
Check stop disk

for damage and wear.
» If there is damage or wear:
–
Change the stop disk.
19.38
Assembling the countershaft
Info
Use new lock rings in every repair job.
–
Oil all parts carefully before assembling.
–
Check the countershaft. ( P. 123)
600311-11
–
Fix countershaft

in the vise with the geared end facing downward.
Specification
Use soft jaws.
–
Mount needle bearing

and second-gear idler gear

with the recesses facing upward.
–
Mount stop disk

and lock ring

.
–
Mount the fourth-gear sliding gear

with the shift groove facing upward.
–
Mount lock ring

.
–
Mount stop disk

and needle bearing

.
–
Mount the third-gear idler gear

with the shifting dogs facing downward.
–
Mount the fifth-gear idler gear

with the sleeve facing downward.
–
Mount spacer disk

and stop disk

.
–
Mount needle bearing

and reverse-gear idler gear

with the recesses facing upward.
–
Mount stop disk

and lock ring

.
–
Mount sliding sleeve

and stop disk

.
–
Mount needle bearing

and first-gear idler gear

with the collar facing upward.
–
Mount stop disk

.
–
Take the countershaft out of the vise.
–
Finally, check all gear wheels for smooth operation.