KTM 85 SX 2004 User Manual

Repair manual KTM 85 SX Art No 3.206.008-E
6-4
Mounting the shift mechanism
– Insert the locking spring
1
into the housing as indicated in the
illustration.
– Mount the locking lever
2
with the roll facing the engine case,
preload and mount the circlip
3
with the sharp edge facing up.
– Push the locking lever backwards with a screwdriver and mount the
shift drum locating device on the shift roller.
– Degrease and apply Loctite 243 to the thread of bolt
4
and use the
bolt to fasten the shift drum locating device to 10 Nm.
–Grease the shaft seal ring of the shift shaft.
– Carefully grease the preassembled shift shaft and carefully insert it
together with the stop disk (15x25x0.5 mm) in the engine case. Push
back the shift rail
5 and insert the shift shaft in the engine case all
the way up to the stop.
– Mount the foot shift lever and shift through all gears. When shifting
through the gears, turn the countershaft. Then remove the foot shift
lever.
Mounting kickstarter
– Oil the bearing bore for the kickstarter shaft.
– Insert the preassembled kickstarter shaft and the stop disk
6
(15x25x1 mm) in the bearing bore so that the nose A on the ratchet
gear spring is located between the two bars and the nose
B on the
ratchet gear is behind the stop
C.
– Apply Loctite 243 to the thread of the bolt
7 (M5x25 mm).
– Mount the spring bushing
8, preload the starter spring and put into
place (see illustration) and tighten the bolt to 6 Nm.
1
5
4
A
B
C
6
7
8
2
3

KTM 85 SX 2004 Specifications

General

Brand	KTM
Model	85 SX 2004
Category	Motorcycle
Language	English