KTM 85 SX 2004, Repair Manual, Page: 53 / 89

5-14
Repair manual KTM 85 SX
Art No 3.206.008-E
Checking the kickstarter for wear
Take all components off the kickstarter shaft and clean them.
Kickstarter gear
1
Check the toothing for wear and the bearing for clearance.
Kickstarter idler gear
2
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 3
Check the inclined surface and the toothings for wear.
Kickstarter shaft
4
Check bearing positions and toothings for wear and damage. Check the
oil bore for the kickstarter gear for unobstructed passage.
Ratchet gear spring
5
Check the ratchet gear spring for wear.
NOTE: The ratchet gear spring must be clamped by the ratchet gear and
may not move freely.
Preassembling the kickstarter shaft
– Fix the kickstarter shaft
4
with the toothed end facing up in the vise
(use protective jaws).
– Mount the circlip 6 .
– Slide the kickstarter ratchet gear
3
and the ratchet gear spring on the
kickstarter shaft so that the nose
A
is located on the left side of the
hole
B
(see illustration).
– Slip on the kickstarter pinion
1
with the toothing facing down.
– Fix the kickstarter spring
8
in the hole in the kickstarter shaft and
slide the driving hub
9
with the recess
C
over the end of the
kickstarter spring.
LOCTITE 243
LOCTITE 243
1
2
3
6
5
9
8
4
A
B
C
9
8