KTM 125 - Transmission; Assembling the Main Shaft

Transmission
Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following
parts for wear and grooves:
● Bearing sleeves
● Pivot points of the main shaft and countershaft and pivot points of the idler gears
● Shift dogs of the gears
● Tooth faces of all gears
● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears
● Check the profiles of all control gears for smooth operation
Thoroughly clean all parts, exchange damaged components. New axial securing elements
should be mounted whenever repair work is performed.
Assembling the main shaft
– Clamp the main shaft into a vise (use protective jaws) with the toothed end facing
downwards.
– Carefully grease all parts before mounting them.
– Mount the bearing sleeve
1 (22x25x11.1 mm) on the main shaft. Then put the 5
th
idler
gear 2 on the shaft with the shifting claws facing upwards.
– Put the stop disc
3 (22.2x27.8x1 mm) onto the shaft and mount the axial securing
element 4.
–Mount the 3
rd
/4
th
sliding gear 5 with the small gear facing downwards and mount the
axial securing element
6.
– Put the stop disc 7 (22.2x27.8x1 mm) onto the shaft.
– Mount the bearing sleeve
8 (22x25x11.1 mm) and the 6
th
idler gear 9 with the recess
for the shifting claws facing downwards.
–Mount the 2
nd
fixed gear bk and the stop disc bl (17.2x26x1 mm).
– Then check all gears for smooth operation.
5-17C
X
1
5
6
7
8
9
10
11
3
4
2
X
! ATTENTION !
When replacing gears, watch
out for this mark !