Mounting The Shift Mechanism; Mounting Kickstarter - KTM 85 SX 2004 Repair Manual

2
1
5
A

Mounting the shift mechanism

– Insert the locking spring
illustration.
– Mount the locking lever
preload and mount the circlip
3
– 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
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
4
together with the stop disk (15x25x0.5 mm) in the engine case. Push
back the shift rail
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.
B
– Insert the preassembled kickstarter shaft and the stop disk
(15x25x1 mm) in the bearing bore so that the nose
gear spring is located between the two bars and the nose
ratchet gear is behind the stop
C
6
– Apply Loctite 243 to the thread of the bolt
– Mount the spring bushing
7
place (see illustration) and tighten the bolt to 6 Nm.
8
1
into the housing as indicated in the
2 with the roll facing the engine case,
3
with the sharp edge facing up.
5 and insert the shift shaft in the engine case all
C
.
7
(M5x25 mm).
8
, preload the starter spring and put into
6-4
4
and use the
6
A
on the ratchet
B
on the