KTM 85 SX 2004, Repair Manual, Page: 52 / 89

5-13
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 countershaft
– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Slide on the 2nd idler gear
1
with the collar facing down.
– Mount the circlip
2
(21 SW) with the sharp edge facing up.
– Slip on the 6th sliding gear
3
with the shift groove facing up and
mount the circlip
4
(21 SW).
– Slip on the 3rd idler gear 5 with the collar facing up and the 4th idler
gear 6 with the collar facing down.
– Mount the circlip
7
(21 SW) with the sharp edge facing up.
– Mount the 5th sliding gear
8
with the shift groove facing down.
– Slip on the stop disk
9
(15x25x0.5) and the needle bearing
bk
.
– Slide on the 1st gear idler
bl
with the notches in the contact surface
facing down and slip on the stop disk
bm
(15x25x1).
– Finally, check all of the gears for smooth operation.
7
1
8
6
2
3
4
5
9
10
11
12