KTM 85 SX 2004, Repair Manual, Page: 31 / 89

Repair manual KTM 85 SX
Art No 3.206.008-E
4-2
– Clean the engine thoroughly.
– Clamp the engine into the workstand.
– Remove the kickstarter.
Draining gear oil
NOTE: Drain the gear oil in a warm condition before the engine is
dismounted, otherwise the gear oil may run out through the main shaft
when the clutch slave cylinder is removed.
– Unscrew plug
1
, allowing oil to drain.
Dismounting of sprocket and shift lever
– Remove the circlip
2
and pull the engine sprocket off of the
countershaft together with the distance bushing and O-ring located
behind the engine sprocket.
– Undo the bolt 3 and remove the shift lever.
– Remove the push rod
4
and the ball positioned behind the push rod
from the main shaft.
Dismounting of cylinder head, cylinder and piston
– Unscrew the 6 collar bolts
5
and remove cylinder head and the two
O-rings.
NOTE: If you are replacing the spark plug, loosen it before you dismount
the cylinder head.
– Undo the bolts
6
and remove the control cover together with the
gasket.
1
2
3
4
5
6