KTM 85 SX 2004, Repair Manual, Page: 60 / 89

6-5
– Oil the bearing position of the starter idler and slide on the stop disk
(15x25x0.5 mm).
– Mount the starter idler
1
on the bearing pin with the high collar
facing the engine case .
– Slip on the stop disk (15x25x0.5 mm) and mount the circlip with the
sharp edge facing outwards.
Mount primary drive and clutch
– Grease crankshaft seal ring.
– Slide the oiled O-ring (18.77 x 1.78 mm) on the crankshaft and slip
on the distance sleeve.
– Mount the woodruff key and slide the primary pinion
2
on the
crankshaft.
– Apply the special tool 470.29.003.000 as shown.
– Decrease the HH bolt (M10x1.25x20), apply Loctite 243 and tighten
to 80 Nm.
– Mount the stop disk 3 (20x32x2 mm) and the bushing 4 on the
main shaft.
– Mount the outer clutch hub, supporting plate (18.5x35x1.5 mm), the
driver and a new lock washer.
– Position clutch holder 470.29.003.000 5 and tighten hexagon nut
with 60 Nm.
– Remove the clutch holder and secure the hexagon nut by bending
both brackets of the lock washer upwards.
– Insert the pressure piece
6
and the axial needle bearing together
with the washer
7
in the main shaft.
2
1
4
3
5
6
7