KTM 85 SX 2004, Repair Manual, Page: 51 / 89

5-12
Repair manual KTM 85 SX
Art No 3.206.008-E
Transmission
Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
– Mainshaft and countershaft pivot points including idler gears
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
gears
– Easy operation of gear-change
– Check the friction bearings in the idler gears for score marks and a
flawless condition
Carefully clean components and replace damaged components.
NOTE:
– Always place circlips with sharp edge facing the components secured,
ensuring that they are not overexpanded (use special pliers).
– Check that after any repair of the transmission, circlips should axially
not move more than 0.20 mm and must not seize between stop discs.
– Apply graphite paste (MOS2) to the idler gears before you mount
them.
Assembly mainshaft
– Fix mainshaft in vice with toothed end upwards (use covered clamps).
– Oil all parts before assembly.
– Slide on the 5th idler gear
1
with the shifting dogs facing up.
– Mount the circlip
2
(19 SW) with the sharp edge facing up.
– Slide on the 3rd and 4th gear sliding gear
3
with the larger gear
facing down.
– Mount the circlip
4
(19 SW) with the sharp edge facing up and slide
on the 6th gear idler
5
with the dogs facing down.
– Slide on the stop disk (20.3x26x0.4) 6 and the mount the fixed 2nd
gear 7 together with the stop disk 8 (16x26x1).
– Finally, check all of the gears for smooth operation.
1
4
7
8
6
5
3
2