Checking The Kickstarter For Wear; Preassembling The Kickstarter Shaft - KTM 85 SX 2004 Repair Manual

LOCTITE 243
A
C
9
8
2

Checking the kickstarter for wear

B
Take all components off the kickstarter shaft and clean them.
Kickstarter gear
Check the toothing for wear and the bearing for clearance.
Kickstarter idler gear
Check the bearing for clearance and seizing marks. Check the toothing
for wear. It is constantly engaged with the outer clutch hub.
Kickstarter ratchet gear
Check the inclined surface and the toothings for wear.
Kickstarter shaft
Check bearing positions and toothings for wear and damage. Check the
oil bore for the kickstarter gear for unobstructed passage.
Ratchet gear spring
Check the ratchet gear spring for wear.
9
NOTE: The ratchet gear spring must be clamped by the ratchet gear and
may not move freely.
8

Preassembling the kickstarter shaft

– Fix the kickstarter shaft
(use protective jaws).
– Mount the circlip
– Slide the kickstarter ratchet gear
kickstarter shaft so that the nose
B
hole
– Slip on the kickstarter pinion
– Fix the kickstarter spring
slide the driving hub
kickstarter spring.
LOCTITE 243
1
3
1
2
3
4
5
4
with the toothed end facing up in the vise
6
.
3
and the ratchet gear spring on the
A
(see illustration).
1
with the toothing facing down.
8
in the hole in the kickstarter shaft and
9
with the recess
5-14
5
4
6
is located on the left side of the
C
over the end of the