KTM 400-660 LC4 1998-2005, Repair Manual

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5-22E
Important note regards working on transmission
– Fix the main shaft or countershaft, respectively, in the vise (use
special vise jaws to avoid damaging of the shafts) and remove the
gear wheels.
– Clean and check all parts.
Always use new lock washers when performing repair work on the
transmission !
Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
Check the pivot points of the transmission shafts.
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
Check the needle bearings of the idler gears.
Assembling the counter shaft
– Mount counter shaft in vise with collar facing downwards.
– Oil and mount needle cage
1
.
– Slide 2nd gear
2
over needle cage with collar facing downwards.
– Mount stop disc
3
(22.7x32.0x1.50 mm) with clearance towards
gear wheel and circlip
4
with sharp edge facing upwards.
– Mount 5th gear
5
with shift groove facing upwards.
– Fit circlip
6
with sharp edge down and stop disc
7
(22.7x32.0x1.50
mm).
– Mount needle cage 8 and fit 4th gear 9 with shift dogs facing up.
– Mount stop disc bk (22.7x32.0x1.50 mm) and circlip bl with sharp
edge facing up.
– Fit 3rd gear
bm
with shift groove down and mount stop disc
(22.2x35.0x1.50 mm)
bn
.
– Mount needle cage
bo
, 1st gear
bp
with collar facing up and fit stop
disc (20.2x35.0x1.0 mm)
bq
.
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
Check all gears for smooth operation.
1
3
2
4
5
6
7
8
9
10
11
12
13
14
15
16