KTM 200 - Shifting Mechanism; Preassembling the Shifting Shaft (up to Model 2000); Preassembling the Shifting Shaft (Model 2001 Onwards)

Repair manual KTM 125 / 200
Art No 3.206.005 -E
Shifting mechanism
Shift forks 1
Check the blade A for wear.
Shift roller
2
Check the shift grooves B for wear.
Ensure that the shift roller rests properly in the grooved ball bearing
3.
Check the grooved ball bearing bl in the shift roller for wear. To replace
it, remove the Seeger circlip ring
bm and pull the grooved ball bearing
out of the shift roller (slide seat). Mount the Seeger circlip ring with the
sharp edge pointing to the outside.
Shift ratchet
4
Check the contact surface toward the gear shifting gate for wear. The
shift ratchets must not jam when mounted.
Grooved ball bearing
3
Check for smooth operation.
Sleeves
5
on the driving pin for the shift shaft must be free of pressure marks.
Shift rails
bn
Impact-test the shift rails on a planar surface. Check shift rails for score
and seizing marks. The easy operability of the shift forks on the shift rails
must be ensured.
Preassembling the shifting shaft (up to model 2000)
–Grease the 2 stop discs 6 (14.3x20x1 mm), and slide them onto the
shift shaft.
– Mount the return spring
7 on the shift shaft; the two legs of the
spring must rest against bracket
C of the shift shaft.
– Put the disc
9 (14,3x20x1 mm) on the shaft, then mount the circlip
8 with the sharp edge facing upwards in the groove of the shift
shaft.
– Put on the disc
9 (14,3x20x1 mm).
Preassembling the shifting shaft (model 2001 onwards)
– Mount the return spring 7 on the shift shaft; the two legs of the
spring must rest against bracket
C of the shift shaft.
– Put discs
6 (14,2x22x1,5 mm) and 9 (14,3x20x1 mm) on the shaft,
then mount the circlip
8 with the sharp edge facing upwards in the
groove of the shift shaft.
– Put on the disc
9 (14,3x20x1 mm).
5-16C
6
7
8
9
9
up to 2000
C
7
6
8
9
9
2001 onwards