Dismounting Of Intake Flange And Reed Valve Housing; Parting Of Engine Housing Halves; Dismounting Of Gearshift Mechanism And Transmission - KTM 85 SX 2004 Repair Manual

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Dismounting of intake flange and reed valve housing

– Remove the 4 collar bolts
– Remove the intake flange and the reed valve housing together with
the gasket.

Parting of engine housing halves

– Top ignition-gear upwards and remove all 10 housing bolts.
– Loosen the 2 engine fixtures on the engine work stand.
– Lift left-hand housing half with suitable tools by on the bosses
provided, or part with a few light plastic mallet blows against the
countershaft from the right-hand housing half.
L
EVERING APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED
THE SEAL FACES ARE EASILY DAMAGED

Dismounting of gearshift mechanism and transmission

– Remove the stop disk
– Pull the 2 pressure springs
– Remove the stop disk
NOTE: Pay attention to the stop disks
engine case (they may adhere to the inside of the case).
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– Pull out the shift rails and swing the shift forks aside.
– Pull the shift drum and stop disk out of the bearing seat.
– Remove the shift forks.
NOTE:
– When dismounting, pay attention to the needle rollers
could stay behind in the shift drum.
– Since the shift forks differ from each other, be sure to mark them
accordingly when you remove them.
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CAUTION
!
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from the main shaft.
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out of the shift rails.
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from the shift drum.
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and
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,
SINCE
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when you separate the
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, which