Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
5-12C
Shift mechanism
Shift forks 1
Check shift fork blades A and shift roller driving pin B for signs of wear.
Shift roller
2
Check shift grooves for wear.
Check position of shift roller in grooved ball bearings
3.
Slide plate
4
Check slide plate at meshing points C for wear.
Check return surface
D for wear (renew, if strongly notched).
Check that guide pin
E is securely fixed and check for wear.
Sliding guides
Check sliding guides (excess between guide pin and shift quadrant not to
be more than 0.7 mm / 0.03 in).
Grooved ball bearings
3
Check grooved ball bearings for easy movement.
Shift mechanism
Assemble shift mechanism (see below) and check free play between slide
plate
4 and shift quadrant 5. Free play should be 0.40 - 0.80 mm (0.016
- 0.032 in).
Preassembly of shift shaft
– Fix shift shaft in vice at shorter end (use covered clamps).
– Mount slide plate
4 with guide pins downwards, hook guide pins into
shift quadrant
5.
– Mount pressure spring
6.
– Slide on spring guide
7, slide on return spring 8 with offset end
upwards over the spring guide and lift offset end over bolt
9 (see
illustration).
–Mount the stop disc
bk (14x30x1 mm).
0,40 -
0,80 mm
9
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