5-18C
Repair manual KTM 125 / 200
Art No 3.206.000 -E
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 countershaft
– Clamp the countershaft into the vise (use protective jaws!) with the toothed end facing
downwards.
– All parts must be carefully greased before mounting.
– Mount the bearing sleeve
1 (25x28x9.7 mm) and the 2
nd
idler gear 2 with the recess for
the shifting claws facing upwards.
–Mount the stop disc
3 (25.2x32x1 mm) and the axial securing element 4 on the
countershaft.
–Mount the 6
th
idler gear 5 with the shift groove facing upwards, then mount the stop
disc
6 (22.2x28x1 mm).
– Mount the bearing sleeve 7 (22x25x8.1 mm), the 4
th
idler gear 8 and the stop disc 9
(22.2x30x2.5 mm).
– Mount the bearing sleeve
bk (22x25x8.1 mm), the 3
rd
idler gear bl, the stop disc bm
(22.2x27.8x1 mm) with internal teeth and the axial securing element bn.
–Mount the 5
th
sliding gear bo with the shift groove facing downwards and the stop disc bp
(17.2x26x1 mm).
– Mount the bearing sleeve bq (17x20x9.7 mm), the 1
st
idler gear br with the collar facing
upwards and the stop disc
bs (17.2x26x1 mm).
7
8
5
6
4
3
2
1
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