Servicing On Individual Components; Important Note Regards Working On Engine Housing - KTM 85 SX 2004 Repair Manual

SERVICING ON INDIVIDUAL COMPONENTS

WORKING ON THE RIGHT-HAND HOUSING HALF . . . . . . . . . . . . . . . . . . .5-2
WORKING ON THE LEFT-HAND HOUSING HALF . . . . . . . . . . . . . . . . . . . .5-3
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
NIKASIL COATING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
CYLINDER EXHAUST CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
PREASSEMBLING THE CONTROL FLAP AND THE CYLINDER . . . . . . . . . . .5-6
DISMOUNTING THE CENTRIFUGAL TIMER AND THE WATER PUMP . . . . .5-7
PREASSEMBLING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
REPLACE OUTER CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
DISASSEMBLING THE SHIFTING SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
SHIFTING MECHANISM - CHECKING PARTS FOR WEAR . . . . . . . . . . . . . .5-11
PREASSEMBLING THE SHIFTING SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
ASSEMBLY MAINSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
ASSEMBLY COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
CHECKING THE KICKSTARTER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . .5-14
PREASSEMBLING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . .5-14

IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING

Read through the following section before commencing work. Then determine the assembly sequence so that the
engine housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the
housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface
without damaging it. A wooden panel is best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a
suitable mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an
engine housing temperature of approx. 150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the
housing must be replaced.
INDEX
5-1
5