Mounting Clutch Discs And Pressure Cap; Mounting Clutch Cover - KTM 85 SX 2004 Repair Manual

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Mounting clutch discs and pressure cap

– Oil lining discs before mounting.
– Starting with a lining disk, alternately insert 7 lining disks and 6 clutch
NOTE: Mount the clutch disks with the sharp edge facing up.
– Place pressure cap into position; fit clutch springs, spring retainer and
– Tighten the collar bolts crosswise. Do not apply more than 6 Nm to

Mounting clutch cover

– Make sure the 2 dowels are mounted in the engine housing.
– Grease the shaft seal ring on the kickstarter shaft and fix a new clutch
– Center the shift shaft to allow the bolt
– Apply silicone to area
B
– Fit collar bolts (see sketch for bolt lengths) and tighten with 8 Nm.
– Then check easy running of all shafts.
NOTE: If you cannot mount the clutch cover, check whether the
kickstarter spring and the shift shaft are in the right position.
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disks. A lining disk must be the last disk on top.
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collar bolts .
prevent damaging of the threads in the inner clutch hub.
cover seal with a small amount of grease.
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shanks of the return spring.
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and carefully mount the preassembled clutch
cover. Turn the crankshaft slightly to allow the centrifugal timer to
engage in the primary pinion.
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to engage between the two
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6-6
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