KTM 85 SX 2004, Repair Manual, Page: 58 / 89

6-3
– Fix the 4 pressure springs
1
with ample amounts of grease in the
gearshift rails.
– Oil gearshift rails and insert them into the gearshift forks (short
gearshift rail toward drive shaft). Insert gearshift rails into the casing
bores as far as they will go.
NOTE: It must now be possible to gently turn gear shafts.
– Mount stop disk
2
(16x26x1 mm) on the main shaft.
– Fix the spacing washer
3
(15x20x0.5 mm) to the shift drum with a
little grease.
Assembling the engine housing
– Remove engine fastener from engine work stand.
– Make sure that both fitting collars are in place in the right housing
half and that the stop disk on the main shaft and the spacing washer
are mounted on the shift drum.
– Apply light coat of grease to sealing surfaces of the housing and
position new gasket.
– Grease shaft seal rings in left-hand half and place left-hand half in
position.
– Position bolts and tighten with 8 Nm.
– Fix engine in work stand.
M6 x ...
25
40
40
25
25
40
25
40
40
40
1
2
3