5-21E
Repair manual KTM LC4 Art.-Nr. 3.206.014 -E
Important note regards working on transmission
– Fix the main shaft or countershaft, respectively, in the vise (use
special vise jaws to avoid damaging of the shafts) and remove the
gear wheels.
– Clean and check all parts.
Always use new lock washers when performing repair work on the
transmission !
Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
Check the pivot points of the transmission shafts.
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
Check the needle bearings of the idler gears.
Assembling the main shaft
– Mount the main shaft in a vise with the gearwheel facing
downwards (use protective jaws).
– Mount the needle cage
1 and slide the 3rd gear 2 with the shift
dogs facing upwards.
–Mount stop disc
3 (22.7x32x1.5 mm) and the circlip 4 with the
sharp edge facing up.
–Mount 4th gear
5 with the shift groove facing down.
– Secure it with the circlip
6 with the sharp edge down and mount
the stop disc
7 (22.7x32x1.5 mm).
– Mount needle cage
8 and 5th gear 9 with the shift dogs down.
– Mount 2nd gear
bk and stop disc bl (20.2x35x1 mm).
NOTE: Check all gears for smooth operation.
1
5
6
7
8
9
10
11
2
3
4
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