KTM 690 LC4 2007, Repair Manual

Page: 52 / 95

5-19
General information on servicing the transmission
Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gears and check the following parts for wear or
seizing marks:
– Bearings
– Pivot points on the main shaft and countershaft and pivot points on the idler gears
– Gear dogs
– Tooth faces on all gears
– Tooth profiles on the main shaft and countershaft and the corresponding gears
– Check all sliding gears for smooth operation in the profile
Carefully clean all parts and replace any damaged parts.
Always mount new circlips when repairing the transmission.
Assembling the main shaft
– Clamp the main shaft in a vise with the toothed end facing down (use protective jaws).
– Carefully lubricate all parts prior to mounting.
– Mount the split needle bearing
1
, mount the 5-speed idler gear
2
with the shift dogs
facing up.
– Mount the stop disk
3
(20x32x1mm) and the circlip
4
.
– Mount the 3rd/4th gear sliding gear
5
with the small gear facing down; mount the shaft
ring
6
.
– Mount the stop disk
7
and split needle bearing
8
.
– Mount the 6th gear idler gear
9
with shift dogs facing down.
– Mount the 2nd gear fixed gear
bk
with the collar facing down; mount the stop disk
bl
(20x32x1mm).
– Finally, check all gears for smooth operation.
NOTE:
3
and
bl
are identical.
1
2
3
4
5
6
7
9
8
bk
bl