Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
5-16C
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
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 (0.006 in) and must not seize between stop
discs.
Assembly countershaft
– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Push stop disc
1 (26x40x1,5 mm) onto countershaft.
–Mount 3
rd idler gear 2 with shift dog recesses upwards and circlip 3
(25x2 mm) with sharp edge upwards.
–Mount 5
th sliding gear
4 with shift groove downwards, stop disc 5
(22,2x33x1,5 mm), needle cage 6, 1st free gear 7 with shift dog
recesses downwards and stop disc
8 (17,2x34x1,5 mm) with collar
upwards on the countershaft.
– Remove countershaft from vice and fix again with toothed end
upwards.
–Mount 4
th sliding gear 9 with shift dog upwards, stop disc bk
(28,2x40x1,5 mm), needle cage bl, 2nd idler gear bm with shift dog
recesses downwards and stop disc
bn (25,7x40x1,5 mm).
– Finally check all gears for easy running.
7
8
5
6
4
3
2
1
9
10
11
12
13
