KTM 690 LC4 2007, Repair Manual

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5-20
Repair manual KTM 690 LC4
Art.-No. 3.206.045-E
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 countershaft
– Clamp the countershaft 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
and 2nd gear idler gear
2
on the countershaft with
the protruding collar facing down.
– Mount the thrust washer
3
and the lock ring
4
.
– Mount the 6th gear sliding gear
5
with the shift groove facing up.
– Mount the lock ring
6
and the stop disk
7
.
– Mount the 2 split needle bearings
9
+
bl
and the 4th gear idler gear
8
with the collar
facing up.
– Mount the 3rd gear idler gear
bk
with the collar facing down.
– Mount the stop disk
bm
and lock ring
bn
.
– Mount the 5-speed sliding gear
bo
with the shift groove facing down; mount the stop disk
bp
(22x31.7x1mm).
– Mount the needle bearing
bq
, 1st gear idler gear
br
with the recess facing down; mount the stop disk
bs
(20x32x1mm).
NOTE:
–
3
,
7
and
bm
are identical.
–
9
and
bl
are identical.
1
2
3
4
5
6
7
9
8
bk
bl
bp
bo
bn
bm
bq
br
bs