KTM 85 SX 2004, Repair Manual, Page: 32 / 89

4-3
– Detach the ball socket
1
from the control lever.
– Remove the 4 collar nuts
2
on cylinder base and remove cylinder.
– Remove the cylinder base gasket.
– Cover the crankcase.
– Place piston on wooden jig and remove both piston pin locking pins.
– Expel piston pin from piston without exerting undue force. Use a
suitable mandrel if necessary.
– Remove piston and piston pin needle-bearing from conrod eye.
!
CAUTION
!
T
HE PISTON PIN MUST NEVER BE FORCED OUT WITH A PUNCH
. T
HIS WOULD
DAMAGE THE CONROD BEARING
.
Dismounting of clutch cover
– Remove the sealing element.
– Remove the locking screw on the adjusting shaft
3
, detach the ball
socket from the adjusting shaft and pull the adjusting shaft
4
out of
the housing.
– Remove collar bolts and clutch cover including gasket.
NOTE:
– The water pump cover
5 , the outer cover 6 and the cover lid 7 do
not need to be removed. The water pump and the centrifugal timer
remain in the clutch cover.
– Only the outer cover
6
needs to be removed to work on the clutch.
1
2
5
3
4
6
7