KTM 690 SMC 2008, Repair Manual

Page: 130 / 227

30/ENGINE - WORK ON INDIVIDUAL PARTS
128
18.38
Assembling countershaft
Info
Use new lock rings in every repair job.
–
Oil all parts carefully before assembling.
–
Check the transmission. ( p. 126)
1 1
2 2
4 4
5 5
6 6
7 7
9 9
8 8
bl bl
bk bk
bm bm
8 8
bo bo
bn bn
bp bp
bq bq
br br
3 3
300128-02
–
Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
–
Mount needle bearing

and the second-gear idler gear

on the countershaft with the protruding collar facing downward.
–
Mount stop disk

and lock ring

.
–
Mount the sixth-gear sliding gear

with the shift groove facing upward.
–
Install lock ring

and stop disk

.
–
Mount needle bearing

and the fourth-gear idler gear

with the collar facing upward.
–
Mount needle bearing

and the third-gear idler gear

with the collar facing downward.
–
Install stop disk

and lock ring

.
–
Mount the fifth-gear sliding gear

with the shift groove facing downward and stop disk

.
–
Mount needle bearing

, first-gear idler gear

with the groove facing downward and stop disk

.
–
Finally, check all gear wheels for smooth operation.