KTM 85 SX 2004 - Checking the Kickstarter for Wear; Preassembling the Kickstarter Shaft

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