KTM 250 SX - Manual (Page 49)

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
LOCTITE 243
LOCTITE 243
LOCTITE 243
LOCTITE 243
1
1
2
3
3
4
D
E
C
6
7
8
10
5
1
A
B