KTM 690 ENDURO EU 2008 User Manual

30/ENGINE - WORK ON INDIVIDUAL PARTS 129
19.32Checking shift mechanism
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300120-01
– Check the shift forks  (see ) for damage and wear (visual check).
» If there is damage or wear:
– Change the shift fork and the idler/fixed gear pair.
– Check shift grooves  of shift drum  for wear.
» If the shift groove is worn:
– Change the shift roller.
– Check the seat of the shift drum in the bearings .
» If the shift roller is not seated correctly:
– Replace the shift drum and/or the bearing.
– Check bearing  for stiffness and wear.
» If the bearings do not move freely or are worn:
– Replace the bearings.
– Check the needle bushing  for stiffness and wear.
» If the needle bushing does not move freely or is worn:
– Replace the needle bushing.
– Check the shift rail  on a flat surface for run-out.
» If there is run-out:
– Change the shift rail.
– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate  in contact areas  for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface  on the sliding plate for wear.
» If deep notches are present:
– Change the sliding plate.
– Check guide pin  for looseness and wear.
» If the guide pin is loose and/or worn:
– Change the sliding plate.
– Preassemble the shift shaft. ( p. 129)
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– Check the clearance  between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift
quadrant
0.40… 0.80 mm (0.0157…
0.0315 in)
» If the measured value does not equal the specified value:
– Change the sliding plate.
19.33Preassembling shift shaft
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– Fix the short end of the shift shaft in a vise.
Guideline
Use soft jaws.
– Mount sliding plate  with the guide pin facing down and attach the guide pin to
the shift quadrant.
– Mount preload spring .
– Push on spring guide , push return spring  over the spring guide with the offset
end facing upward and lift the offset end over abutment bolt .
– Mount stop disk .

KTM 690 ENDURO EU 2008 Specifications

General

Brand	KTM
Model	690 ENDURO EU 2008
Category	Motorcycle
Language	English