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KTM 85 SX 2004 User Manual

KTM 85 SX 2004
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85 SX
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.008-E
REPAIRMANUAL2004

Table of Contents

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KTM 85 SX 2004 Specifications

General IconGeneral
Displacement84.9 cc
IgnitionCDI
StarterKickstarter
Transmission6-speed
Final DriveChain
Front BrakeDisc
Rear BrakeDisc
Front Tire70/100-17
Rear Tire90/100-14
Engine TypeSingle-cylinder, 2-stroke
Power25 hp
Fuel SystemCarburetor
Rear SuspensionMono shock

Summary

SERVICE-INFORMATIONS

GENERAL INFORMATION

CARBURETOR ADJUSTMENT

Details on adjusting the carburetor, including idle speed, part-throttle, and full-throttle ranges.

BLEEDING OF THE HYDRAULIC CLUTCH

Step-by-step guide for bleeding the hydraulic clutch system using specific fluids.

SPECIAL TOOLS

Lists and illustrates specialized tools required for engine work on the 85 SX model.

CLEANING

Provides instructions on how to clean the motorcycle.

STORAGE

Outlines procedures for storing the motorcycle for extended periods.

REMOVING AND REFITTING ENGINE

REMOVING THE ENGINE

Step-by-step instructions for safely removing the engine from the motorcycle frame.

INSTALLING THE ENGINE

Detailed guide for reinstalling the engine into the motorcycle frame, including torque specifications.

BLEEDING THE COOLING SYSTEM

Instructions for refilling and bleeding the motorcycle's cooling system.

ADJUSTING THE THROTTLE CABLE

Procedure for checking and adjusting the throttle cable play for optimal performance.

DISASSEMBLING ENGINE

DRAINING GEAR OIL

Step-by-step guide for draining the engine's gear oil.

DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON

Detailed steps for disassembling the cylinder head, cylinder, and piston assembly.

DISMOUNTING THE CLUTCH

Steps for disassembling the clutch assembly.

PARTING OF ENGINE HOUSING HALVES

Steps for separating the engine housing halves.

DISMOUNTING OF THE CRANKSHAFT

Instructions for removing the crankshaft.

SERVICING INDIVIDUAL COMPONENTS

WORKING ON THE RIGHT-HAND HOUSING HALF

Detailed steps for servicing the right-hand engine housing half.

WORKING ON THE LEFT-HAND HOUSING HALF

Detailed steps for servicing the left-hand engine housing half.

CRANKSHAFT

Procedures for servicing the crankshaft, including bearing replacement.

PISTON

Checks and maintenance for the piston, including ring end gap.

CLUTCH

Detailed checks for wear on clutch components like springs, discs, and hub.

ASSEMBLING ENGINE

ASSEMBLING THE ENGINE HOUSING

Procedures for assembling the engine housing halves with gaskets and seals.

MOUNT PRIMARY DRIVE AND CLUTCH

Procedures for mounting the primary drive and clutch components.

MOUNTING PISTON AND CYLINDER

Procedures for mounting the piston and cylinder assembly.

ADJUSTING DIMENSION „X"

How to adjust dimension "X" using base gaskets for correct compression.

ADJUSTING THE IGNITION

Procedure for adjusting the ignition timing.

ELECTRICAL

RESISTOR VALUES OF THE IGNITION SYSTEM - STATOR

Electrical resistance values for the ignition system stator coils at 20° C.

IGNITION COIL

Procedures for measuring the primary and secondary resistance of the ignition coil.

MEASURING STATIC IGNITION VALUES WITH PEAK VOLTAGE ADAPTER

Instructions for measuring ignition system voltages using a peak voltage adapter.

TROUBLE SHOOTING

TROUBLE SHOOTING 85 SX

A chart detailing common engine problems, their causes, and recommended remedies.

TECHNICAL SPECIFICATIONS

TECHNICAL SPECIFICATIONS 85 SX

Detailed technical data for the 85 SX engine, including dimensions, ratios, and settings.

BASIC CARBURETOR SETTING

Specific settings and values for the Keihin PWK 28 carburetor.

TIGHTENING TORQUES - ENGINE

Specified torque values for various engine assembly bolts and nuts.

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE SCHEDULE

Schedule of routine maintenance tasks based on operating hours or mileage.

IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER

Essential checks and maintenance tasks for the rider to perform regularly.

WIRING DIAGRAMS

WIRING DIAGRAM 85 SX

Electrical wiring diagram for the 85 SX model, showing components and connections.

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