Working On The Left-Hand Housing Half - KTM 85 SX 2004 Repair Manual

5-3

Working on the left-hand housing half

Remove all shaft seal rings and use an oven to heat the casing half to
approx. 150°C.
2
3
The bearings usually fall out of their seat of their own accord by
knocking the housinq half on a plane piece of wood when the housing
has a temperature of 150° C.
1
Crankshaft roller bearing
1
Press old roller bearing inwards, press in new ball bearing to the stop
5
with the open side of ball cage downwards (outside). The inner ring on
the crankshaft must also be renewed (see paragraph about crankshaft).
2
Needle bearing of drive shaft
7
Press old grooved ball bearing inward, press new grooved ball bearing
from the inside up to the stop.
3
Grooved ball bearing of countershaft
Press old ball bearing inwards, press in new ball bearing to the stop from
inside.
6
4
Grooved ball bearing of shift roller
Heat the shift drum to approx.150° C.
8
At this temperature the grooved ball bearing will automatically fall out of
the bearing seat.
If necessary, tap the shift drum on a flat wooden surface.
Insert a new grooved ball bearing and press in gently up to the stop.
5
Needle bushing of shift shaft
Remove shaft seal ring and press old needle bushing inwards. Press in
D
new needle bushing from the outside to the collar .
6
Crankshaft seal ring
Press in a new shaft seal ring from the outside until the sealing lip is flush
with the inner surface.
4
7
Counter shaft seal ring
Press in a new shaft seal ring until the sealing lip is flush with the inner
surface.
D
8
Shift shaft seal ring
Press in a new shaft seal ring up to the stop with the sealing lip on the
inside.
When housing half has cooled off, check to see that the bearings are
tight.
5
– Finally check clear passage of the crankshaft roller bearing lubrication
A
bore .
A