KTM 300 1998 User Manual

4
4.15.1 Assembly mainshaft
– Fix mainshaft in vice with toothed end upwards (use covered clamps).
– Oil all parts before assembly.
– Mount the split needle cage
1
on mainshaft, push 5
th
idler gear
2
over it with collar downwards.
– Place internally toothed stop disc
3
in position and mount circlip (25x1.64 mm)
4
with sharp
edge upwards.
– Place 3
rd
sliding gear
5
in position with shift groove downwards, mount circlip
6
with sharp edge
downwards and internally toothed stop disc
3
.
– Mount the split needle cage
1
, 4
th
idler gear
7
with shift dogs downwards 2
nd
gear
8
with collar
downwards and stop disc
9
(20.2x32x1.5 mm).
– Finally check all gears for easy running.
4.15 Transmission
Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
A)NEEDLE BEARING
B
)MAINSHAFT AND COUNTERSHAFT PIVOT POINTS INCLUDING IDLER GEARS
C
)SHIFT DOGS AND GEAR WHEELS
D
)TOOTH FACES OF ALL GEARS
E
)TOOTH PROFILE OF MAINSHAFT AND COUNTERSHAFT AND CORRESPONDENDING GEARS
F
)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
). C
HECK THAT AFTER ANY REPAIR OF THE TRANSMISSION
, CIRCLIPS
SHOULD AXIALLY NOT MOVE MORE THAN
0,2
MM (0.006 IN) AND MUST NOT SEIZE BETWEEN STOP DISCS.
4.15.2 Assemble countershaft
– Fix countershaft in vice with toothed end (use covered clamps).
– Oil all parts before assembly.
– Push stop disc
1
(25,2x40x1,5 mm) onto countershaft.
– Mount 3
rd
idler gear
3
with shift dog recesses upwards and circlip (25x4 mm)
4
with sharp edge
upwards.
– Mount 5
th
sliding gear
5
with shift groove downwards, stop disc
6
(24,2x36x1,5 mm), needle
cage
2
, 1
st
free gear
7
with shift dog recesses downwards and stop disc
8
(17,2x34x1,5-2 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
(28,2x42x1,5 mm), needle cage
bl
, 2
nd
idler gear
bm
with shift dog recesses downwards and stop disc
bn
(25,2x40x1,5 mm).
– Finally check all gears for easy running.
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KTM 300 1998 Specifications

General

Brand	KTM
Model	300 1998
Category	Engine
Language	English