2004-2006 KTM 85SX 105SX Engine Repair Manual Paper

Description

This 2004 2005 2006 KTM 85SX 105SX Engine Repair Manual is an authorized reproduction of the original, out of print manual. It covers ONLY the engine on the following motorcycle models:

2004-2006 KTM 85 SX / 105 SX

Table of Contents

General Information
Carburetor Adjustment
Bleeding Of The Hydraulic Clutch
Changing Front Brake Fluid
Changing Rear Brake Fluid
Checking Brake Pads And Brake Discs
Special Tools
Cleaning
Storage

Removing And Installing The Engine
Dismounting The Engine
Mounting The Engine
Bleeding The Cooling System
Adjusting The Throttle Cable

Dismantling The Engine
Clamp The Engine Into The Mounting Rack Removing Of Kickstarter
Draining Gear Oil
Dismounting Of Sprocket And Shift Lever
Dismounting Of Zylinder Head Cylinder And Piston
Dismounting Of Clutch Cover
Dismounting The Clutch
Dismounting Of The Primary Drive
Dismounting The Kickstarter Unit
Dismounting The Shift Mechanism
Dismounting The Ignition
Dismounting Of Intake Flange And Reed Valve Housing
Parting Of Engine Housing Halves
Dismounting Of Gearshift Mechanism And Transmission
Dismounting Of The Crankshaft

Servicing Individual Components
Working On The Right-hand Housing Half
Working On The Left-hand Housing Half
Crankshaft
Piston
Piston Ring End Gap
Checking Cylinder For Wear
Recoated Cylinder
Nikasil Coating Of Cylinder
Cylinder Exhaust Control System
Preassembling The Control Flap And The Cylinder
Dismounting The Centrifugal Timer And The Water Pump
Preassembling The Clutch Cover
Reed Valve Housing Intake Flange
Clutch
Replace Outer Clutch Hub
Disassembling The Shifting Shaft
Shifting Mechanism – Checking Parts For Wear
Preassembling The Shifting Shaft
Assembly Mainshaft
Assembly Countershaft
Checking The Kickstarter For Wear
Preassembling The Kickstarter Shaft

Assembling The Engine
Crankshaft
Transmission
Assembling The Engine Housing
Mounting Shift Mechanism
Mounting Kickstarter
Mount Primary Drive And Clutch
Mounting Clutch Discs And Pressure Cap
Mounting Clutch Cover
Mounting Piston And Cylinder
Adjusting Dimension €žx€œ
Adjusting Control Flap (dimension €žz€œ)
Mounting The Ignition
Adjusting The Ignition
Mounting Cylinder Head
Mounting Reed Valve Housing And Intake Flange
Mounting Engine Sprocket
Mounting The Kickstarter And Shift Lever
Fill In Transmission Oil
Checking Gear Oil Level

Electrical
Resistor Values Of The Ignition System – Stator
Ignition Coil
Measuring Static Ignition Values With Peak Voltage Adapter
Spark Plug

Troubleshooting

Technical Data
85 Sx Model 2004
Engine
Carburetor
Chassis
Standard Adjustment Shock Absorber / Fork
105 Sx Model 2004
Engine
Carburetor
Chassis
Standard Adjustment Shock Absorber / Fork
85 Sx Model 2005
Engine
Carburetor
Carburetor Setting
Chassis
Standard Adjustment Shock Absorber / Fork
85 Sx Model 2006
Engine
Carburetor
Carburetor Setting
Chassis
Standard Adjustment Shock Absorber / Fork
Tolerances And Fitting Clearances
Tightening Torques Engine
Tightening Torques Chassis

Lubrication And Maintenance Schedule
85 Sx / 105 Sx Model 2004
85 Sx Model 2005
85 Sx Model 2006

Wiring Diagrams