Clutch Cover; Kickstarter Shaft - KTM S5-E Repair Manual

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4.7 Clutch cover

– Use a suitable pair of pliers to remove the circlip from the kickstarter shaft.
– Pull the ratchet gear together with the ratchet gear spring off the kickstarter shaft
(kickstarter shaft must be turned from outside).
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– Take the kickstarter shaft out of the clutch cover.
P
IVOT POINT OF THE KICKSTARTER SHAFT
Check the pivot point of the kickstarter shaft in the clutch cover for grooves or signs
of wear.
– Slightly grease the pivot point and insert the preassembled kickstarter shaft (see
4.8.1) into the clutch cover.
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– Pull the ratchet gear onto the kickstarter shaft, the teething facing the kick-
starter gear, while at the same time hooking the ratchet gear spring into the ope-
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ning in the housing.
– Put the Seeger circlip on the kickstarter shaft with the sharp edge facing out-
wards.

4.8 Kickstarter shaft

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– Take O-ring and washer
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– Take circlip , washer and kickstarter gear off the kickstarter shaft.
K
ICKSTARTER SHAFT
Check teeth and pivot points of the kickstarter shaft for damage or grooves caused
by constant wear.
K
ICKSTARTER GEAR
Check teeth and pivot point of the kickstarter gear for damage or grooves caused by
constant wear.
R
ATCHET GEAR
Check the teeth of the ratchet gear for signs of wear.
The ratchet gear must turn easily in the ratchet gear spring but it should not jump
out of the spring eye.
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off the kickstarter shaft.