KTM 85 SX 2004 - Preassembling the Shifting Shaft; Shifting Mechanism - Checking Parts for Wear; Disassembling the Shifting Shaft

5-11
Disassembling the shifting shaft
– Clamp the shifting shaft into the vise (use protective jaws).
– Remove the return spring
1
and twist the spring holder
2
off the
shifting shaft
3
.
–Take the shift quadrant
4
off the shifting shaft
3
together with the
slide plate
5
and the pressure spring
6
.
– Remove the pressure spring
6
, shift the slide plate
5
and take it out
of the shift quadrant
4
.
Shifting mechanism - Checking parts for wear
Shift forks 7
Check shift fork blades A and shift roller driving pin B for signs of wear.
Shift roller
8
Check shift grooves for wear.
Check position of shift roller in grooved ball bearings
9.
Slide plate
5
Check the contact surfaces for the locking piece for wear. Check the
return surface at the slide plate for wear (replace it if deep grooves are
detected).
Pressure spring
6
Check the preload of the pressure spring for the slide plate.
Grooved ball bearings
9
Check grooved ball bearings for easy movement.
Preassembling the shifting shaft
– Insert the slide plate into the shift quadrant and slide it.
– Then insert the pressure spring.
–Degrease the thread of the spring holder and apply a small quantity
of Loctite 243. Position the slide plate together with the shift
quadrant on the shifting shaft and secure both with the spring holder.
– Mount the return spring (15x25x05 mm).
NOTE: When mounting the return spring keep in mind that the offset
must be on top.
LOCTITE 243
LOCTITE 243
LOCTITE 243
1
7
2
5
6
7
3
4
9
8
7
A
B
1
2