Disassembling The Shifting Shaft; Shifting Mechanism - Checking Parts For Wear; Preassembling The Shifting Shaft - KTM 85 SX 2004 Repair Manual

5-11
LOCTITE 243
1
1
LOCTITE 243
5
8
9
7

Disassembling the shifting shaft

2
– Clamp the shifting shaft into the vise (use protective jaws).
– Remove the return spring
shifting shaft
– Take the shift quadrant
slide plate
– Remove the pressure spring
of the shift quadrant

Shifting mechanism - Checking parts for wear

Shift forks
Check shift fork blades
Shift roller
Check shift grooves for wear.
Check position of shift roller in grooved ball bearings
Slide plate
Check the contact surfaces for the locking piece for wear. Check the
return surface at the slide plate for wear (replace it if deep grooves are
detected).
Pressure spring
Check the preload of the pressure spring for the slide plate.
Grooved ball bearings
Check grooved ball bearings for easy movement.

Preassembling the shifting shaft

– Insert the slide plate into the shift quadrant and slide it.
– Then insert the pressure spring.
– Degrease the thread of the spring holder and apply a small quantity
of Loctite 243. Position the slide plate together with the shift
quadrant on the shifting shaft and secure both with the spring holder.
– Mount the return spring (15x25x05 mm).
NOTE: When mounting the return spring keep in mind that the offset
must be on top.
2
4
3
6
A
7
B
1
3
.
4 off the shifting shaft
5
and the pressure spring
6
4 .
7
A
and shift roller driving pin
8
5
6
9
LOCTITE 243
7
and twist the spring holder
3 together with the
6
.
5
, shift the slide plate and take it out
B
for signs of wear.
9
.
2 off the