To Next Page

To Previous Page

5-20

Repair manual KTM 690 LC4 Art.-No. 3.206.045-E

General information on servicing the transmission

Clamp the main shaft or countershaft in a vise (use protective jaws).

Remove the gears and check the following parts for wear or seizing marks:

– Bearings

– Pivot points on the main shaft and countershaft and pivot points on the idler gears

– Gear dogs

– Tooth faces on all gears

– Tooth profiles on the main shaft and countershaft and the corresponding gears

– Check all sliding gears for smooth operation in the profile

Carefully clean all parts and replace any damaged parts.

Always mount new circlips when repairing the transmission.

Assembling the countershaft

– Clamp the countershaft in a vise with the toothed end facing down (use protective jaws).

– Carefully lubricate all parts prior to mounting.

– Mount the split needle bearing

1 and 2nd gear idler gear 2 on the countershaft with

the protruding collar facing down.

– Mount the thrust washer

3 and the lock ring 4.

– Mount the 6th gear sliding gear

5 with the shift groove facing up.

– Mount the lock ring

6 and the stop disk 7.

– Mount the 2 split needle bearings

9 + bl and the 4th gear idler gear 8 with the collar

facing up.

– Mount the 3rd gear idler gear

bk with the collar facing down.

– Mount the stop disk

bm and lock ring bn.

– Mount the 5-speed sliding gear

bo with the shift groove facing down; mount the stop disk bp (22x31.7x1mm).

– Mount the needle bearing

bq, 1st gear idler gear br with the recess facing down; mount the stop disk bs (20x32x1mm).

NOTE:

–

3, 7 and bm are identical.

–

9 and bl are identical.

KTM 690 LC4 2007 User Manual

Questions and Answers: