KTM 250 SX-F 2005, Repair Manual

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5-22
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
General information on servicing the transmission
Clamp the main shaft or countershaft in the vise (use protective jaws).
Remove the gears and check the following parts for wear and seizing marks:
– Bearings
– Pivot points on the main and countershaft and pivot points on idler gears
– Shift dogs
– Tooth faces on all gear wheels
– Tooth profiles on the main shaft and countershaft as well as the corresponding gear wheels
– Profiles of all sliding gears for smooth operation
Carefully clean all parts and replace any damaged parts.
Mount new circlips whenever you repair the transmission.
Assembling the countershaft
– Clamp the countershaft in the vise with the toothed end facing down (use protective
jaws).
– Carefully oil all parts before mounting.
– Mount the idler gear sleeve(25x28x9.7mm)
1
and the 2nd gear idler gear
2
on the
countershaft with the recess for the shift dogs facing up.
– Mount the thrust washer
3
(25x35x1mm) and the lock ring
4
with the sharp edge
facing up.
– Mount the 6th gear sliding gear
5
with the shift groove facing up.
– Mount the lock ring
6
and the stop disk
7
(25.2x32x1mm).
– Mount the 2 split needle bearings
9
+
bl
and the 4th gear idler gear
8
with the recess
for the shift dogs facing down.
– Mount the 3rd gear idler gear
bk
with the recess for the shift dogs facing up.
– Mount the stop disk
bm
(25.2x32x1mm) and the lock ring
bn
.
– Slip on the 5th gear sliding gear
bo
with the shift groove facing down and the stop disk
bp
(20x31.9x1mm).
– Mount the needle bearing
bq
, 1st gear idler gear
br
with the recess facing down and the
stop disk
bs
(17.2x30x1mm).
1
2
3
4
5
6
7
9
8
bk
bl
bp
bo
bn
bm
bq
br
bs