KTM 85 SX 2004, Repair Manual, Page: 57 / 89

Repair manual KTM 85 SX
Art No 3.206.008-E
6-2
– Secure the right-hand housing half in the engine work stand.
Crankshaft
– Insert crankshaft from above through grooved ball bearing and push
carefully as far as stop.
!
CAUTION
!
W
HEN PUSHING IN CRANKSHAFT
,
MAKE SURE CONROD IS FACING CYLINDER
.
NOTE: To make it easier to mount the crankshaft, heat the crankshaft
bearing with a hot air blower.
Transmission
– Oil driving pin 1 for the shift forks and mount.
– Fix the lower stop disc on the countershaft with a small amount of
grease.
– Mount drive shaft together with countershaft, and insert them into
the bearings as far as they will go.
– Oil shift forks prior to mounting.
– Shift fork
2
with the shorter shift dog belongs to the main shaft.
– Mount the two other shift forks at the countershaft, using the marks
applied before disassembly for better orientation.
!
CAUTION
!
A
LL OF THE SHIFT FORKS ARE DIFFERENT SO GO BY THE MARKS MADE DURING
DEMOUNTING WHEN YOU MOUNT THEM AGAIN
.
NOTE: If you forgot to make a mark before disassembling, mount the
shift forks at the countershaft so that the greatest distance is between
the driving pins.
– Fit the shift forks in the sliding gears and insert the shift drum and the
spacing washer (25x32x0.5 mm) in the grooved ball bearing.
– Attach the shift forks to the shift roller.
!
CAUTION
!
W
HEN INSERTING THE SHIFT FORKS
,
MAKE SURE THE DRIVING PINS DO NOT FALL OUT
OF THE SHIFT FORKS
.
1
2