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85 SX 2004
KTM 85 SX 2004 User Manual
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5-8
Repair manual KTM 85 SX
Art No 3.206.008-E
LOCTITE 243
LOCTITE 243
Reed valve housing, intake flange
NOTE: Reed paddles
1
gradually lose tension through operation,
r
esulting in power loss. Damaged or worn reed paddles must be
r
eplaced.
!
CAUTION
!
S
ECURE
ALL
BOL
TS
OF
THE
REED
VAL
VE
HOUSING
WITH
L
OCTITE
243.
Intake flange
2
Check for firm mounting and for signs of damage.
1
2
46
48
Table of Contents
Important Information
7
Table of Contents
15
General Information
15
Carburetor Adjustment
17
Idling Range – A, Adjusting the Idle Speed
17
Part-Throttle Range – C
17
Full Throttle Range – D
17
Bleeding of the Hydraulic Clutch
18
Special Tools – Engine 85 Sx
19
Use after Period of Storage
20
Cleaning
20
Storage
20
Dismounting and Mounting the Engine
21
Removing the Engine
23
Installing the Engine
26
Refilling/Bleeding the Cooling System
28
Disassembling the Engine
29
Dismounting of Cylinder Head, Cylinder and Piston
31
Dismounting of Sprocket and Shift Lever
31
Draining Gear Oil
31
Dismounting of Clutch Cover
32
Dismounting of the Primary Drive
33
Dismounting the Clutch
33
Dismounting the Kickstarter Unit
34
Dismounting the Shift Mechanism
34
Dismounting the Ignition
35
Dismounting of Intake Flange and Reed Valve Housing
36
Dismounting of Gearshift Mechanism and Transmission
36
Parting of Engine Housing Halves
36
Dismounting the Crankshaft
37
Servicing on Individual Components
39
Important Note Regards Working on Engine Housing
39
Working on the Right-Hand Housing Half
41
Working on the Left-Hand Housing Half
42
Crankshaft
43
Piston
43
Piston Ring End Gap
43
Nikasil Coating of Cylinder
44
Checking Cylinder for Wear
44
Recoated Cylinder
44
Cylinder Exhaust Control System
45
Preassembling the Control Flap and the Cylinder
45
Dismounting the Centrifugal Timer and the Water Pump
46
Preassembling the Clutch Cover
46
Reed Valve Housing, Intake Flange
47
Clutch
48
Replace Outer Clutch Hub
49
Preassembling the Shifting Shaft
50
Shifting Mechanism - Checking Parts for Wear
50
Disassembling the Shifting Shaft
50
Transmission
51
Assembly Mainshaft
51
Assembly Countershaft
52
Checking the Kickstarter for Wear
53
Preassembling the Kickstarter Shaft
53
Assembling the Engine
55
Assembling the Engine Housing
58
Mounting the Shift Mechanism
59
Mounting Kickstarter
59
Mount Primary Drive and Clutch
60
Mounting Clutch Discs and Pressure Cap
61
Mounting Clutch Cover
61
Mounting Piston and Cylinder
62
Adjusting Dimension „X“
63
Adjusting Control Flap (Dimension “Z“)
64
Mounting the Ignition
65
Adjusting the Ignition
65
Mounting Cylinder Head
66
Mounting the Intake Flange and Reed Valve Housing
66
Mounting Engine Sprocket
66
Checking Gear Oil Level
67
Mounting the Kickstarter and Shift Lever
67
Fill in Transmission Oil
67
Electrical
69
Resistor Values of the Ignition System - Stator
71
Ignition Coil
71
Measuring Static Ignition Values with Peak Voltage Adapter
72
Spark Plug (NGK BR 10 ECMVX)
72
Trouble Shooting
73
Trouble Shooting
75
Technical Specifications
77
Technical Specifications - Engine 85 Sx 2004
79
Standard Adjustment - Shock Absorber
80
Technical Specifications – Chassis 85 Sx 2004
80
Standard Adjustment – Fork
80
Tolerances and Fitting Clearances
81
Gasket Thicknesses
81
Tightening Torques - Engine
81
Tightening Torques - Chassis
81
Lubrication and Maintenance Schedule
83
Periodic Maintenance Schedule
84
Wiring Diagrams
87
5
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KTM 85 SX 2004 Specifications
General
Brand
KTM
Model
85 SX 2004
Category
Motorcycle
Language
English
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