KTM 250 SX-F 2005, Repair Manual

Page: 71 / 125

Installing the transmission shafts and crankshaft, assembling the
casing halves
– Place the right casing half on the engine work stand in an upright
position.
– Put the two transmission shafts together and insert in the casing
half with one hand while you guide the transmission shafts into the
bearings with the other hand.
NOTE: the countershaft has a stop disk facing the bearing, the main
shaft does not.
– Lay the engine case down and insert the shift forks.
NOTE:
– The smaller shift fork
1
is used for the main shaft, the larger forks
(
2
and
3
) for the countershaft.
– The "one-sided" shift fork
2
is inserted on the bottom, the
"symmetrical" shift fork
3
on top.
– The needle rollers on the shift forks must point towards the shift
drum.
– Mount the shift drum and allow the needle rollers on the shift forks
to engage.
NOTE: the shift drum has a groove
A
without "curves" around its edge;
no shift fork can engage in this shift groove.
– Attach the lower springs to the shift rails
4
with grease and mount
the shift rails; press down on the shift rails to check for smooth
operation.
– Insert the upper springs in the shift rails.
NOTE:
– The conical ends of the springs point towards the outside.
– The shorter shift rail is used for the single shift fork on the main
shaft.
6-2
Repair manual KTM 250 SX-F
Art.-No. 3.206.027-E
1
2
3
4
2
3
A
4
4