Cylinder Exhaust Control System; Preassembling The Control Flap And The Cylinder - KTM 85 SX 2004 Repair Manual

1-cylinder, 2-stroke engine
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LOCTITE 243
12
11
10
LOCTITE 243

Cylinder exhaust control system

Dismantle and clean all exhaust control components, check for signs of wear and damage.
1
Bearing sleeves
– Check bearing sleeves of the control flap for play and easy operation.
2
Control flap
– Clean the control flap. The control flap must not graze inside the exhaust port.
Check the silicone O-ring in the closing cover
9
7
8
5
6
14
3
and the control flap

Preassembling the control flap and the cylinder

– Mount the silicone O-ring (8.03x1.78)
– Push the bearing sleeve
– Fasten the driving disk
– Position the bearing sleeve
– Mount the overload spring
– Push the bearing sleeve
– Insert the preassembled control flap and closing cover
– Apply a thin layer of silicone to the sealing areas and mount the
– Finally, check the exhaust control system for smooth operation.
NOTE: It should be possible to press the control lever
4
2
1
4
for wear and replace if necessary.
grease.
1
outwards.
5
with the bolt facing outwards and the stop
6
plate
with the stop facing inwards with the bolt
yet since this bolt will also be used to adjust the exhaust control
(measurement Z).
9
mount the control lever
with the ball head facing outwards.
bk
Apply Loctite 243 to the thread of the AH bolt
bm
bolt and the spring sleeve
the overload spring to the cylindrical pin and tighten the AH bolt.
1
outwards.
the O-ring (12x2)
3
in the cylinder.
bo
flange
.
against the spring force.
1
3
13
4
on the control flap and
onto the right side with the collar facing
7
. Do not tighten
8
with the collar facing outwards and
with the long shank facing downwards.
bl
and screw in the
several turns. Attach the short shank of
onto the left side with the collar facing
9
5-6
bn
including
further up

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