Home

REPAIRMANUAL2004-2005

1. 9 1 PREASSEMBLING THE CLUTCH COVER 9 1 REED VALVE HOUSING INTAKE FLANGE 9 8 A Am 9 9 REPLACE OUTER CLUTCH HUB 9 10 DISASSEMBLING THE SHIFTING SHAFT 9 11 SHIFTING MECHANISM CHECKING PARTS FOR WEAR 9 11 PREASSEMBLING THE SHIFTING SHAFT 9 11 ASSEMBLY MAINSHAFT 9 12 ASSEMBLY COUNTERSHAFT 9 13 CHECKING THE KICKSTARTER FOR WEAR 9 14 PREASSEMBLING THE KICKSTARTER SHAFT 9 14 IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING Read through the following section before commencing work Then determine the assembly sequence so that the engine housing halves only need to be heated up once before replacing the bearings Having first removed the dowels in order to expel the bearings or remove them with light mallet blows the housing halves must be placed on a suitably large plane surface supporting the whole of the sealing surface without damaging it A wooden panel is best used as a base Bearings or shaft seal rings should not be hammered into their seats If no suitable press is available use a suitable mandrel and hammer them in with great care Cold bearings will practically drop into their seats at an engine housing temperature
2. THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER AVOID OVERHEATING AND PISTON SEIZURE NOTE If the engine does not run properly despite a changed adjustment look for mechanical faults and check the ignition system Basic information on carburetor wear As a result of engine vibrations the throttle valve jet needle and needle jet are subjected to increased wear This wear may cause Carburetor malfunction e g overly rich mixture Therefore these parts should be replaced after 1000 hours of using Idling range A Adjusting the idle speed Operation with closed throttle valve This range is influenced by the position of the air control screw and the idle adjusting screw Only make adjustments when the engine is hot To this end slightly increase the idling speed of the engine by means of the idle adjusting screw Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed Create a round and stable engine speed using the air control screw basic position of the air control screw open by 1 5 turns Then adjust to the normal idling speed by means of the idle adjusting screw Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the engine sputters and sm
3. Turn the rotor in a counterclockwise direction until the upper edge of the piston rests against the setting gauge see drawing Art Nr 3 206 020 E Now turn the stator until the two marks coincide CAUTION BEFORE CHECKING THE IGNITION THE DIMENSION MUST ADJUSTED CORRECTLY Tighten the 3 collar bolts on the stator to 6 Nm Once again check the distance between the edge of the piston and the upper edge of the cylinder using the adjusting plate If necessary readjust the distance by rotating the stator Put on a new gasket and fix the ignition cover by means of the 3 bolts Repair manual KTM 85 SX 105 SX Mounting cylinder head Clean cylinder and cylinder head sealing surface place O rings in grooves Mount cylinder head with water nozzle on the exhaust side Oil the collar nuts at threads and contact faces Mount the collar bolts with new copper gaskets and tighten them crosswise taking three turns to achieve the total tightening torque of 10 Nm n first stage only tighten until slight resistance is felt Mounting the intake flange and reed valve housing Mount a gasket and insert the reed valve housing in the intake port Tighten the intake flange to 6 Nm Mounting engine sprocket Lubricate O ring with oil and slide over counter shaft Slide distance bushing in position so that O ring is in correct position Q Mou
4. Bleeding of the hydraulic clutch Take off cover together with rubber bellows At the slave cylinder of the clutch remove the bleeder nipple It its place mount the bleeder syringe which is filled with SAE 10 e g Motorex Kupplungsfluid 75 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not overflow CAUTION HAVING COMPLETED THE BLEEDING PROCEDURE YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 E G MOTOREX KUPPLUNGSFLUID 75 TO FILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX FIG Ra 0 Fr SPECIAL TOOLS ENGINE 85 SX 105 SX DESCRIPTION 475 29 006 000 HOLZGABEL SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE PART NUMBER Universal engine work stand Clutch rivetting too Loctite 243 blu 6 cm Circlip plier Vent syringe for hydraulic clutch Magneto extractor M 27x1 Protection cap Internal bearing puller 5 7 mm Holding spanner for flywheel Bearing puller Adjusting plate 85 SX Adjusting plate 105 SX Mounting tool inner ring NJ207 Clutch Primary gear holde
5. Finally check the exhaust control system for smooth operation NOTE It should be possible to press the control lever O further up against the spring force 15 LOCTITE 243 g 4 mimo nte the centrifugal timer and the water pump Remove both of the bolts and take off the closing cover together with the O ring Loosen the nut on the centrifugal timer Pull the centrifugal timer O out of the housing Remove both of the bolts and take off the water pump cover together with the gasket Loosen the bolt on the water pump wheel Pull off the water pump wheel and take out the water pump shaft Cleanse all parts and check for wear Check the ball heads on the linkage for play Check the water pump drive wheel for damage or wear Check the grooved ball bearings and for wear NOTE The centrifugal timer does not require any maintenance work or adjustments Replacing the grooved ball bearings for the water pump and the centrifugal timer Remove the shaft seal ring from the water pump and heat the housing half in an oven to approx 150 C When it has reached a temperature of 150 C the bearings will fall out of the bearing seats by themselves when the housing half is tapped on a flat wooden surface Press in new bearings until flush Press in a new shaft seal ring for the water pump from the outside with the sealing lip facing inwards until flush Preassembling the clutch
6. and remove Lift of tank together with spoilers Unhook the two springs of the exhaust pipe Remove the bolt of the front exhaust bracket Remove the bolt of the rear exhaust bracket O Pull exhaust pipe out of the rubber sleeve take of the exhaust pipe Loosen the two hose clamps and remove the carburetor Let the fuel of the float chamber run out into an appropriate basin Putthe carburetor into a clean cloth and lay it on the air filter box Remove the radiator cap Remove drain bolt at the water pump cover and drain cooling liquid Loosen hose clamp and disconnect the radiator hose Unscrew the three bolts on the clutch slave cylinders and the bolt O on the chainguard Remove the chainguard and tilt the clutch slave cylinder to the side 3 206 020 E Art Nr Repair manual KTM 85 SX 105 SX 3 4 Disconnect spark plug connector remove cable tie and disconnect the connector Loosen the bolt on the radiator mounting and pull the wiring harness through Loosen hose clamp and disconnect radiator hose at the cylinder head Remove the two engine fixing bolts and the hexagon nut Dismount the swing arm pivot pull the swing arm towards the rear Lift the engine out of the frame Installing the engine Lift the engine into the frame and correctly position it Slightly grease
7. 122 rolls Steering angle 66 Wheel base 1278 mm Seat height unloaded Ground clearance Dead weight without fuel Rider s body weight max 70 kg Recommended age of rider 10 to 15 years Engine CR 85 STANDARD ADJUSTMENT FORK WP 4357 MXMA 0518Y740 Compression adjuster 34 Rebound adjuster 30 Spring preload 6mm Air chamber length 100 mm STANDARD ADJUSTMENT SHOCK ABSORBER WP 4618 PDS DCC WP 1518Y706 28 LS low speed 2 HS high speed Rebound adjuster 30 Spring 40 215 Compression adjuster Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX TECHNICAL SPECIFICATIONS ENGINE 105 SX 2004 105 SX Design Liquid cooled single cylinder two stroke engine with reed valve intake Displacement 103 96 ccm Bore stroke 52 48 95 mm 2 047 1 927 in unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Oil gasoline ratio 1 40 1 60 when using high grade two stroke oil e g Motorex 2T Crosspower when in doubt please contact your importer Lubrication mixture lubrication Crankshaft bearing deep groove ball bearing cylinder roller bearing Piston pin bearing needle bearing Primary drive straight cut spur gears 19 66 4 Transmission 6 speed claw actuated 11729 Gear ratio 14 28 16 26 19 26 21 325 20721 Transmission oil 0 50 liter engine oil Motorex Topspeed 4T 15W5
8. Repair manual KTM 85 5 105 SX Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 2 2 Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx 500 meters 1600 ft above sea level and the ambient temperature of approx 20 C 68 F mainly for off road use and central European premium grade fuel ROZ 95 Mixing ratio 2 stroke motor oil super fuel 1 40 Basic information of changing the carburetor setting Always start out from the original carburetor setting Essential requirements are a clean air filter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes to other parts of the carburetor will not greatly affect engine performance RULE OF THUMB high altitude or high temperatures gt choose leaner carburetor adjustment low altitude or low temperatures gt choose richer carburetor adjustment A WARNING A ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE AND THEIR USE WILL VOID YOUR WARRANTY ONLY USE HIGH GRADE 2 STROKE ENGINE OIL OF KNOWN BRANDS G MOTOREX CROSS POWER 2T NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON IF YOU USE TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG
9. Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact grease Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE Service Intervals should never be exceeded by more than 5 hours or 500 km Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER 10 5 Before each start After every cleaning For cross country use Once a year Check gear box oil level Check brake fluid level Check brake pads for wear Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Check tightness of screws nuts and hose clamps regularly Check the reed type intake valve for wear Check the clutch shoes for wear Check the l
10. and the ignition coil ground Multimeter display under 10 Q at 20 C Measure the resistance on the secondary side of the ignition coil between the high voltage cable and the ignition coil ground Multimeter display 7900 Q 1500 Q at 20 C NOTE The ignition coils do not need to be removed to measure Measuring static ignition values with peak voltage adapter Measuring conditions cold engine remove starting number plate unscrew sparkplug plug on and hold against ground all plug and socket connectors and ground connections in a non corroding condition depress the kickstarter forcefully at least 5 times for each measurement Check the pulse generator for output signal white red and white blue cables Apply the red measuring tip of the peak voltage adapter to the white red cable and the black measuring tip to the white blue cable disconnect plug to disconnect the CDI unit 6 Multimeter display 10 volts 1 volt Same measurement with CDI unit connected Multimeter display 6 volts 1 volt Check the CDI voltage supply for output voltage green red and black cables Apply the red measuring tip of the peak voltage adapter to the green red cable and the black measuring tip to the black cable disconnect plug Multimeter display 40 volts 5 volts Same measurement with CDI unit connected Multimeter display 35 volts 5 volts Check capacitor charging coil
11. and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Check tightness of bolts nuts and hose clamps regularly H HL u RECOMMENDED INSPECTION OF THE 85 SX 105 SX ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP Check the reed type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear 0 4 PERIODIC MAINTENANCE SCHEDULE 2005 85 SX 1st service after after after 10 hours 20 hours 4000 kilometer or or once a year A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Check gear box oil level Check spark plugs adjust distance between electrodes Check the carburetor connection boot for cracks an
12. cover Grease the shaft seal ring for the water pump and mount the water pump shaft together with the washer 10x14x0 5 mm Mount the water pump wheel apply Loctite 243 to the bolt and tighten together with the washer to 4 Nm Mount the water pump cover and gasket Insert the centrifugal timer in the housing and tighten the self locking nut to 6 Nm Mount a new O ring and mount the closing cover Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 9 8 Reed valve housing intake flange NOTE Reed paddles gradually lose tension through operation resulting in power loss Damaged or worn reed paddles must be replaced CAUTION SECURE ALL BOLTS OF THE REED VALVE HOUSING WITH LOCTITE 243 Intake flange Check for firm mounting and for signs of damage Clutch Thrust bearing check for wear Push rod check for wear length 113 mm Clutch springs 5 clutch springs should have the same length Minimum length 33 mm new 34 mm Replace all 5 springs if necessary 7 Lining discs Minimum thickness 2 8 mm new 3 mm All disks should be plane Check disks for score marks or mechanical damage 6 Steel discs Must be plane check for mechanical damage Inner clutch hub Check the contact surfaces of the steel disks against the driver Check the driver for mechanical damage or score marks Pressure cap Check contact surfaces between lining disc and pressure for signs of m
13. cover bolts Spark plug 10 Nm 30 Nm 60 Nm Loctite 243 80 Nm Loctite 243 60 Nm 8 Nm 20 Nm 6 Nm Loctite 243 12 Nm Loctite 243 12 Nm M10x1 5 M14x1 5 M14x1 25 Reed valve housing Kickstarter 75 Nm 6 Nm 10 Nm TIGHTENING TORQUES CHASSIS Hexagon bolt brake caliper Loctite 243 25 Nm bolt rear brake pads M6 5 Flat head bolt brake discs M6 Loctite 243 10 Nm Hexagon nut front wheel spindle M10x1 5 Hexagon nut rear wheel spindle M20x1 5 Hexagon nut swingarm bolt M14 M16x1 5 Clamping bolts top triple clamp Clamping bolts bottom triple clamp Bolt handlebar clamp AH screw handlebar mount Loctite 243 40 Nm Hexagon nut fork fist 10 Nm Steering head nut HH screw upper lower shock absorber 10 Nm 60 Nm Rear sprocket screws Loctite 243 35 Nm Ball joint for push rod Engine carrier screw M10 Loctite 243 10 Nm Reifenhalter M8 Rim lock Outrigger screw connection 4 5 5 Loctite 243 35 Nm Other chassis bolts nuts 10 15 Nm 25 30 Nm 45 50 Nm 10 1 LUBRICATION AND MAINTENANCE SCHEDULE 10 INDEX 85 SX 105 SX MODEL 2004 10 2 MODEL 2009 10 4 Art Nr 3 206 020 Repair manual 85 5 105 SX 10 2 PERIODIC MAINTENANCE SCHEDULE 200
14. engine 15 dismounted otherwise the gear oil may run out through the main shaft when the clutch slave cylinder is removed Unscrew plug O allowing oil to drain of sprocket and shift lever Remove the circlip and pull the engine sprocket off of the countershaft together with the distance bushing and O ring located behind the engine sprocket Undo the bolt and remove the shift lever Remove the push rod and the ball positioned behind the push rod from the main shaft Dismounting of cylinder head cylinder and piston Unscrew the 6 collar bolts and remove cylinder head and the two O rings NOTE If you are replacing the spark plug loosen it before you dismount the cylinder head Undo the bolts and remove the control cover together with the gasket Detach the ball socket from the control lever Remove the 4 collar nuts on cylinder base and remove cylinder Remove the cylinder base gasket Cover the crankcase Place piston on wooden jig and remove both piston pin locking pins Expel piston pin from piston without exerting undue force Use a suitable mandrel if necessary Remove piston and piston pin needle bearing from conrod eye CAUTION THE PISTON PIN MUST NEVER BE FORCED OUT WITH A PUNCH THIS WOULD DAMAGE THE CONROD BEARING Dismounting of clutch cover Remove the sealing element Remove the locking screw on the adjusting s
15. of approx 150 C After cooling should the bearings fail to lock in the bore they are bound to rotate after warming In that event the housing must be replaced Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 9 2 Working on the right hand housing half Remove all shaft seal rings and use an oven to heat the casing half to approx 150 C The bearings usually fall out of their seat of their own accord by knocking the housing half on a plane piece of wood when the housing has a temperature of 150 C Grooved ball bearing of crankshaft O Press old grooved ball bearing inwards Press in new grooved ball bearing from inside up to the stop Grooved ball bearing of main shaft 6 Press in new ball bearing from inside up to the stop Grooved ball bearing of countershaft Press in new grooved ball bearing from downward to the stop Grooved ball bearing of the shift roller O Press the old bearing towards the inside Press in a new grooved ball bearing from the inside to the stop Needle bushing of the shift shaft O Press old needle bushing inwards press in new needle bushing flush from the outside Grooved ball bearing of centrifugal timer O Use a self made supporting plate to support the puller to avoid damage to the housing see illustration Pull out the bearing using a 5 8 mm inside puller 151 12 018 200 151 12 017 000 Press in new grooved ball bearing to the stop Grooved ball bearing for the
16. piston ring Checking cylinder for wear To check the wear on the cylinder measure the cylinder 20 mm below the upper edge of the running surface using a micrometer Measure the cylinder diameter in the X and the Y axis to detect any ovality Engine Cylinder 0 Piston size 85 47 000 47 012 1 47 013 47 025 2 105 52 000 52 012 1 52 013 52 025 2 Recoated cylinder NOTE If the cylinder diameter is greater than 47 025 mm 85 SX or 52 025 105 SX the Nikasil cylinder must be reconditioned or replaced For reconditioning of the old cylinder all exhaust control components must be removed The intermediate flange remains with the cylinder The piston size is stamped into the bottom of the piston Nikasil coating of cylinder Nikasil is the brand name for a cylinder coating process developed by the piston manufacturer Mahle The name is derived from the two materials used in this process a nickel layer into which the particularly hard silicon carbide is inbedded The main advantages of the Nikasil coating are excellent heat dissipation and thus better power output low wear low weight of the cylinder NOTE The worn coating can be regenerated at low cost provided that the cylinders running surface is flawless Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX LOCTITE 243 11 12 10 Cos u Cylinder exhaust control system Dismantle and clean al
17. place circlips with sharp edge facing the components secured ensuring that they are not overexpanded use special pliers Check that after any repair of the transmission circlips should axially not move more than 0 20 mm and must not seize between stop discs Apply molycote to the idler gears before you mount them Assembly mainshaft Fix mainshaft in vice with toothed end upwards use covered clamps Oil all parts before assembly Slide on the 5th idler gear with the shifting dogs facing up Mount the circlip 19 SW with the sharp edge facing up Slide on the 3rd and 4th gear sliding gear with the larger gear facing down Mount the circlip O 19 SW with the sharp edge facing up and slide on the 6th gear idler with the dogs facing down Slide on the stop disk 20 3x26x0 4 Q and the mount the fixed 2nd gear together with the stop disk O 16x26x1 NOTE the stop disk Q is no longer included starting with engine number B85 400300 since the idler gear for 6th gear O was widened starting with the 2005 model engine number B85 500000 the idler gear for 6th gear has a larger inner diameter and runs on a bushing A stop disk Q is also used In case of repair all transmissions starting with the 2003 model can be equipped with this set also see Technical Informations Finally check all of the gears for smooth operation Transmission Secure mainshaft or countershaft in the vice using soft Jaw cov
18. the two engine fixing bolts and mount but do not tighten yet Slightly grease the swing arm pivot mount the hexagon nut and tighten to 75 Nm CAUTION TIGHTEN THE HEXAGON NUT FIRST SO THE ENGINE WILL NOT BE DEFORMED WHEN MOUNTED THEN TIGHTEN THE ENGINE FIXING BOLTS Connect connector and attach the cable to the frame with a cable tie O Mount the radiator with the bolt 6 Mount the spark plug connector on the spark plug Put the radiator hose onto the connection device on the cylinder head and fix it with the hose clamp Mount the clutch slave cylinder and the chainguard and tighten the three bolts to 10 Nm Tighten the bolt NOTE Two bolts M6x16 are used in position one bolt M6x20 in position Q Mount the bolt of the water pump cover with a new seal ring Connect the radiator hose to the water pump and fix it with the hose clamp Insert the rear end of the carburetor into the carburetor connection boot and the front end into the intake flange Mount and tighten both hose clamps Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 3 6 Push exhaust pipe into the rubber sleeve and tighten the bolt of the rear exhaust pipe bracket Tighten the bolt of the front exhaust pipe bracket 6 Hook the spring Correctly position the tank and mount the bolt with the tank roller tighten the bolt to 10 Nm Co
19. 0 Ignition system Moric Digital 2M1 Spark plug NGK BR 10 ECMVX Electrode gap 0 60 mm 0 0236 in Carburetor flat slide carburetor carburetor see table Coolant 1 liter 0 264 USgal 40 antifreeze 60 water at least 25 C 13 F Air filter wet foam type air filter insert BASIC CARBURETOR SETTING Carburetor Keihin PWK 28 Needle jet 2 6 Idling jet 45 Jet needle N5HG Needle position from top Starting jet 62 Air adjustment screw open 1 5 TECHNICAL SPECIFICATIONS CHASSIS 105 SX 2004 Frame Central chrome moly steel frame Fork telescopic fork White Power 43 MXMA Wheel travel front rear 275 mm 10 83 in 300 mm 11 81 in Rear suspension WP PDS 4618 Progressive Damping System shock absorber Front brake Disc brake 0 220 mm 8 66 in 4 piston Rear brake Disc brake 200 mm 7 87 in 4 piston Tires front 70 100 19 Pirelli MT 32A Tires rear 90 100 16 Pirelli MT 320 Air pressure 1 0 bar 14 403psi Fuel tank capacity 5 1 liter 1 346 USgal Final drive ratio 14 49t Chain 1 2 x 5 16 122 rolls Steering angle 66 Wheel base 1278 mm 50 3 in Seat height unloaded 900 mm 35 43 in Ground clearance 415 mm 16 34 in Dead weight without fuel 68 kg 150 1 Ibs Rider s body weight max 70 kg 154 5 lbs Recommended age of rider 10 to 15 years Engine 105 SX STANDARD ADJUSTMENT SHOCK ABSORBER WP 461
20. 06 020 E Repair manual KTM 85 SX 105 SX Engine fails to start Engine without idle running Engine has not enough power Operating error Fuel supply interrupted Electrode distance too great Plug fouled by oil wet or bridged Ignition wire or connector damaged spark plug Kill button wire or short circuit switch faulty Loose ignition cable connectors Spark too weak Water in the carburetor and jets blocked Idle adjusting screw out of adjustment Ignition system damaged Wear Charred glass fiber yarn in silencer Air filter obstructed Control flap does not work Fuel supply partly interrupted or blocked Loss of compression through loose spark plug Exhaust system damaged Engine has not enough preignition Open fuel tap switch o ignition replenish fuel do not use choke Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out clean carburettor if no fuel leaks out check tank ventilation i e clean fuel tap Reduce electrode distance 0 60 mm Clean spark plug or renew Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate kickstarter a strong spark must be produced at the spark plug f no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstarter f a spark now occurs replace spark plug cap f no spark is produced check
21. 20 E Repair manual KTM 85 5 105 SX TECHNICAL SPECIFICATIONS CHASSIS 85 SX 2005 Frame Central chrome moly steel frame Fork telescopic fork White Power 43 MXMA Wheel travel front rear 2 5 mm 300 mm Rear suspension WP PDS 4618 Progressive Damping System shock absorber Front brake Disc brake 220 mm 4 piston Rear brake Disc brake 200 mm 4 piston Tires front 70 100 17 Pirelli MT 32A 70 100 19 Pirelli MT 32A Tires rear 90 100 14 Pirelli MT 320 90 100 16 Pirelli MT 320 Air pressure 1 0 bar Fuel tank capacity 5 1 liter Final drive ratio 14 461 Chain 1 2 x 5 16 122 rolls Steering angle 66 Wheel base 1278 mm Seat height unloaded 865 mm Ground clearance Dead weight without fuel Rider s body weight Recommended age of rider 10 to 15 years Engine CR 85 STANDARD ADJUSTMENT FORK WP 4357 MXMA 05187A05 Compression adjuster Rebound adjuster Spring STANDARD ADJUSTMENT SHOCK ABSORBER WP 4618 PDS DCC WP 15187A02 17 LS LOW SPEED Compression adjuster 2 HS HIGH SPEED Rebound adjuster 24 Spring 40 215 Spring preload 4 MM Clutch springs length 0 5 mm 0 5 mm as required 0 2 0 3 0 5 mm O rings for 105 form rings O ring Water pump cover O ring TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base Flywheel collar nut Primary pinion bolt Nut for inner clutch hub Crankcase and
22. 4 85 SX 105 SX lst service after after after 10 hours 20 hours 4000 kilometer or 1000 kilometers 2000 kilometers once a year A clean motorcycle can be checked more quickly which saves money Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes Renew spark plugs Check the carburetor connection boot for cracks and leaks Check idle speed setting Check that vent hoses are not damaged or bent Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check oil level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check function of electric systems emergency OFF switch or button e e _ Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks e e 00 Check adjust smooth operation and free travel of handbrake foot brake lever 2 5 Check tightness of brake system bolts Check shock absorber and fork for leaks and function e e Clean dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings Check tightness of all chassis bolts triple clamps fork leg axle passage axle nuts and bolts swing arm bearings shock absorber Check spoke tension and rim joint Check tires and air pressure Check
23. 8 PDS DCC WP 1518Y706 Compression adjuster 17 LS low speed 2 HS high speed Rebound adjuster 24 Spring 40 215 Spring preload 4 mm 0 158 in STANDARD ADJUSTMENT FORK WP 4357 MXMA 0518Y740 Compression adjuster 20 Rebound adjuster 20 Spring 3 N mm Spring preload 6 mm 0 236 in Air chamber length 100 mm 3 937 in Fork oil SAE 5 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX Engine Design TECHNICAL SPECIFICATIONS ENGINE 85 SX 2005 CR 85 Displacement Bore stroke Liquid cooled single cylinder two stroke engine with reed valve intake 84 93 ccm 47 48 95 mm Fuel Oil gasoline ratio Lubrication unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil 1 40 1 60 when using high grade two stroke oil e g Motorex 2T Crosspower when in doubt please contact your importer mixture lubrication Crankshaft bearing Connecting rod bearing Piston pin bearing deep groove ball bearing cylinder roller bearing needle bearing Piston rings Primary drive needle bearing 1 compression ring Clutch Transmission Gear ratio Transmission oil straight cut spur gears 19 661 29 1 gear 2 gear 14 28 3 gear 16 26 4 gear 19 26 5 gear 21 25 6 gear 2 Ignition system Spark plug 0 5 liter engine oil Motorex Topspeed 4T 15W50 Moric Digital 2M1 Electrode gap Carburetor Coola
24. AND NEVER TRY TO KNOCK THE BEARING INNER RING FREE THE CRANKSHAFT WEBS MAY BE COMPRESSED AND THE CON ROD PLUG AND BEARING MAY BE DAMAGES THEREBY MAKING THE CRANKSHAFT UNUSABLE NOTE Distance adjustment of the main bearings is not requested See Technical Informations Piston If a used piston is to remain in service then the following should be checked 1 Piston running surface Check for pressure marks seizing marks minor friction marks can be removed with a fine abrasive stick 2 Piston ring groove The piston ring may not jam in the groove Use an old piston ring or sandpaper 400 grit to clean the groove 3 The piston ring anti rotation device must fit tightly in the piston and may not be worn 4 Check piston rings for wear and check end gap The piston is measured at the piston skirt transverse to the piston pin 32 mm below the top as shown in the illustration The smallest cylinder diameter minus the largest piston diameter determines the piston fitting clearance Piston fitting clearance 0 045 0 07 mm Wear limit O 10 mm Piston ring end gap nsert piston ring into the cylinder and adjust Piston ring must be approx 10 mm from top of cylinder The end gap now be checked with feeler gauge Piston ring end gap max 0 40 mm NOTE If the end gap is greater check piston and cylinder for wear If piston and cylinder wear are within the permitted tolerance limits replace the
25. ART NR 3 206 020 E MANUAL 89 SX 109 SX REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE R PARATION MANUAL DE REPARACI N Ing Ni nk une fom 7 REPAIRMANUAL2004 2005 85 SX 105 SX PME KTM Group Partner 10 11 12 13 14 19 16 SERVICE INFORMATIONS GENERAL INFORMATION REMOVING AND REFITTING ENGINE DISASSEMBLING ENGINE SERVICING INDIVIDUAL COMPONENTS ASSEMBLING ENGINE ELECTRICAL TROUBLE SHOOTING TECHNICAL SPECIFICATIONS PERIODIC MAINTENANCE SCHEDULE WIRING DIAGRAMS Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX IMPORTANT INFORMATION UPDATING INSTRUCTIONS To be able to continue using the existing loose leaf repair instructions simply print the following pages and insert them in the existing repair instructions 1 3 7 9 11 19 25 26 43 44 51 63 64 65 67 77 94 3 4 to 3 5 34t035 00 o 441045 44448 512t0513 52 43 680612 68642 911094 9 10110103 1010105 11 1 to 11 2 KTM REPAIR MANUAL IN LOOSE LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER Put the index 3 205 44 into the binder Put the front page of the repair manual 210x297 mm into the transparent pocket provided for this purpose on the outside of the binder Put the spine label 1 0x45 mm into the transparent pocket provided for this purpose on the spine of the binder Put the summary list
26. E THE EXHAUST TO RUST USE AFTER PERIOD OF STORAGE Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season 3 1 DISMOUNTING AND MOUNTING THE ENGINE 3 INDEX DISMOUNTING THE ENGINE 3 2 MOUNTING THE ENGINE nennen 3 5 BLEEDING THE COOLING SYSTEM 3 7 ADJUSTING THE THROTTLE CABLE 3 7 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX Art Nr 3 206 020 E Repair manual KTM 85 5 105 SX 3 2 Removing the engine Before removing the engine thoroughly clean the entire motorcycle Let the motorcycle cool down before commencing to remove the engine Danger of burns Jack the motorcycle up on a stable supporting device Remove the bolt on the seat slightly lift the back of the seat and pull off towards the rear Close the fuel tap and disconnect the hose Remove the chain joint and take off the chain Undo the bolt
27. asesorar Acordar MERE STANDARD ADJUSTMENT SHOCK ABSORBER FORK 105 SX MODEL 2004 ENGINE csi ER CARBURETOR erica rara aia aa ra CHASSIS sar a an ae a mare STANDARD ADJUSTMENT SHOCK ABSORBER FORK 89 SX MODEL 2005 E nn ahnen CARBURETOR za susanne parada aw e aci Sos CARBURETOR SETTING EEG GUAE REESE SEX X RA ONASSIS van ann R a STANDARD ADJUSTMENT SHOCK ABSORBER FORK TOLERANCES AND FITTING CLEARANCES TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS 9 2 TECHNICAL SPECIFICATIONS ENGINE 85 SX 2004 Engine CR 85 Design Liquid cooled single cylinder two stroke engine with reed valve intake Displacement 84 93 ccm Bore stroke 47 48 95 mm Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Oil gasoline ratio 1 40 1 60 when using high grade two stroke oil e g Motorex 2T Crosspower when in doubt please contact our importer Lubrication mixture lubrication Crankshaft bearing deep groove ball bearing cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston rings 1 compression ring Primary drive straight cut spur gears 19 66 t Clutch multiple di
28. chain rear sprockets and chain guides for wear fitment and tension Lubricate chain WHEELS CHASSIS BRAKES ADD ON PARTS CARBURETOR ENGINE Check clearance of wheel bearings at least every 2 years once a year or 20000 km Check function of exhaust control Complete maintenance of shock absorber Complete maintenance of fork Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact grease Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 km MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 10 3 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each After every cleaning For cross country use Check gear box oil level Check brake fluid level Check brake pads for wear Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure
29. d leaks Check that vent hoses are not damaged or bent Check cooling system for leaks check quantity of antifreeze ENGINE CARBURETOR Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check oil level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check function of electric systems emergency OFF switch or button Check brake fluid level lining thickness brake lining ADD ON PARTS Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake system screws Bleed fork legs Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passageaxle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and chain guides for wear fitment and tension Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least every 2 years once a year or 20000 km Check function of exhaust contro Complete maintenance of shock absorber Complete maintenance of fork Clean and grease steering head bearings and gasket elements Clean and adjust carburetor
30. de the driving hub with the recess over the end of the kickstarter spring Art Nr 3 206 020 E Repair manual 85 SX 105 SX ASSEMBLING THE ENGINE INDEX ERANKSHAPE ans saca aa em TRANSMISSION dd E ows 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 4 ADJUSTING CONTROL FLAP DIMENSION Z 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 6 1 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 6 2 Secure the right
31. echanical damage and score marks Outer clutch hub Check start surfaces of clutch discs on for wear If indentations exceed 0 50 mm replace outer clutch hub Check the friction bearing inner ring and the bushing for wear or score marks Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 9 10 Replace outer clutch hub Drill open the clutch rivets in area of retaining bracket and remove parts Check 6 absorbing elements for signs of mechanical damage replace all 6 where applicable When using the special tool 470 29 027 000 make sure the longer side of the bolts rest on the rivets Apply the special tool 470 29 027 000 as shown screw together and clinch the rivets with the press LOCTITE 243 ae CA K 7 e ES LOCTITE 243 4 gt SR 347 Disassembling the shifting shaft Clamp the shifting shaft into the vise use protective jaws Remove the return spring O and twist the spring holder off the shifting shaft Take the shift quadrant off the shifting shaft together with the slide plate and the pressure spring Remove the pressure spring shift the slide plate and take it out of the shift quadrant 0 Shifting mechanism Checking parts for wear Shift forks Check shift fork blades and shift roller driving pin for signs of wear Shift roller O Check shift grooves for wear Check positi
32. ecrease the HH bolt M10x1 25x20 apply Loctite 243 and tighten to 80 Nm Mount the stop disk 20x32x2 mm and the bushing on the main shaft Mount the outer clutch hub supporting plate 18 5x35x1 5 mm the driver and a new lock washer Position clutch holder 470 29 003 000 and tighten hexagon nut with 60 Nm Remove the clutch holder and secure the hexagon nut by bending both brackets of the lock washer upwards Insert the pressure piece Q and the axial needle bearing together with the washer in the main shaft Art Nr 3 206 020 E Repair manual KTM 85 5 105 SX 6 6 Mounting clutch discs and pressure cap Oil lining discs before mounting Starting with a lining disk alternately insert 7 lining disks and 6 clutch disks A lining disk must be the last disk on top NOTE Mount the clutch disks with the sharp edge facing up Place pressure cap into position fit clutch springs spring retainer and collar bolts Tighten the collar bolts crosswise Do not apply more than 6 Nm to prevent damaging of the threads in the inner clutch hub Mounting clutch cover Make sure the 2 dowels are mounted in the engine housing Grease the shaft seal ring on the kickstarter shaft and fix a new clutch cover seal with a small amount of grease Center the shift shaft to allow the bolt to engage between the two shanks of the return spring Apply silicone to area O a
33. ed Safety rules common in the work shop have also not been listed We take it for granted that the repairs are made by qualified profesionally trained mechanics Read through the repair manual before beginning with the repair work A WARNING A STRICT COMPLIANCE WITH THESE INSTRUCTIONS 15 ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB CAUTION NON COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC NOTE POINTS OUT USEFUL TIPS Use only ORIGINAL KTM SPARE PARTS when replacing parts The KTM high performance engine is only able to meet user expectations if the maintenance work Is performed regularly and professionally 150 9001 _ REG NO 12 100 6061 In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality KTM Sportmotorcycle AG 5230 Mattighofen Austria All design and assembly modification rights reserved by KTM SPORTMOTORCYCLE AG AUSTRIA All rights reserved REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in To keep improving the quality of our repair manuals we request mechanics and shop foremen to assist us as follows If you find any errors or inaccuracies in one of our repair manual whether these are technical
34. ength of the clutch springs Check the cylinder and piston for wear Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear Check the exhaust control for proper functioning and smooth running 11 1 WIRING DIAGRAMS INDEX 89 547 IOISN Geena an Ener nee sn ea Ns 11 2 Art Nr 3 206 020 E Repair manual 85 5 105 SX generator stop button black 09910 0 0 SIUM paJ e bl black orange O uoo uou 19 05 2003 85 5 105 SX Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX Cable colours bl black ye yellow bu blue en green re red wh white br brown or orange pi pink grey pu purple
35. errors Incorrect or unclear repair procedures tool problems missing technical data or torques inaccurate or Incorrect translations or wording etc please enter the error s in the table below and fax the completed form to us at 0043 7742 6000 5349 NOTE to table Enter the complete item no for the repair manual in column 1 e g 3 206 020 E You will find the number on the cover page or in the left margin on each right page of the manual Enter the corresponding page number in the repair manual e g 5 7c in column 2 Enter the current text inaccurate or incomplete in column 3 by quoting or describing the respective passage of the text If your text deviates from the text contained in the repair manual please write your text in German or English if possible Enter the correct text in column 4 Your corrections will be reviewed and incorporated in the next issue of our repair manual Item no of repair manual Current text Correct text Additional suggestions requests or comments on our Repair Manuals in German or English Name mechanic shop foreman Company work shop 2 1 GENERAL INFORMATION 2 INDEX CARBURETOR ADJUSTMENT 2 2 BLEEDING OF THE HYDRAULIC CLUTCH 2 3 SPECIAL TOOLS osos 3 om dn es oie 2 4 CLEANING eu essere 2 5 STORAGE 2 5 Art Nr 3 206 020 E
36. ers Remove gears and check the following for wear Needle bearing Mainshaft and countershaft pivot points including idler gears Shift dogs and gear wheels Tooth faces of all gears Tooth profile of mainshaft and countershaft and correspondending gears Easy operation of gear change Check the friction bearings in the idler gears for score marks and a flawless condition Carefully clean components and replace damaged components NOTE As Always place circlips with sharp edge facing the components secured ensuring that they are not overexpanded use special pliers Check that after any repair of the transmission circlips should axially not move more than 0 20 mm and must not seize between stop discs Apply molycote to the idler gears before you mount them sembly countershaft Fix countershaft in vice with toothed end use covered clamps Oil all parts before assembly Slide on the 2nd idler gear with the collar facing down Mount the circlip 21 SW with the sharp edge facing up Slip on the 6th sliding gear with the shift groove facing up and mount the circlip O 21 SW Slip on the 3rd idler gear with the collar facing up and the 4th idler gear Q with the collar facing down Mount the circlip 21 SW with the sharp edge facing up Mount the 5th sliding gear with the shift groove facing down Slip on the stop disk 15x25x0 5 and the needle bearing Slide on the 1st gear idler with the n
37. es in the electric system you should treat the short circuit button with a contact spray STORAGE If you want to put your motorcycle away for longer periods of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggressive contaminations Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel tap and wait until the engine dies off by itself In this way the carburetor jets are prevented from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kickstarter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate basin Correct tire pressure Lubricate bearing points of the control levers footrests etc as well as the chain he storage place should be dry and not be subjected to overly great temperature fluctuations Cover the motorcycle with an air permeable tarpaulin or blanket Do not use airtight materials as possible humidity might not be able to escape and thereby cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD HE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUS
38. for output voltage black red and green white cables Apply the red measuring tip of the peak voltage adapters to the black red cable and the black measuring tip to the green white cable disconnect plug Multimeter display 270 volts 20 volts Same measurement with CDI unit connected Multimeter display 230 volts 20 volts Check the primary voltage output for ignition coil control orange cable Apply the red measuring tip of the peak voltage adapter to the ground and the black measuring tip to the orange cable CDI unit and ignition coil connected Multimeter display 230 volts 20 volts NOTE If no voltage can be measured during the test check the respective cable for continuity before replacing any parts Spark plug NGK BR 10 ECMVX Set the electrode distance Electrode distance 0 60 mm Insulator Check for cracks and fissures CAUTION ALWAYS USE A SPARK PLUG WITH RESISTOR OTHERWISE PROBLEMS CAN OCCUR IN THE CDI UNIT 8 1 TROUBLE SHOOTING 8 INDEX TROUBLE SHOOTING 85 SX 105 SX 8 2 Art Nr 3 206 020 E Repair manual 85 5 105 SX 8 2 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the trouble shooting chart in order to find the cause of error TROUBLE CAUSE REMEDY Art Nr 3 2
39. gearshift rail toward drive shaft Insert gearshift rails into the casing bores as far as they will go NOTE It must now be possible to gently turn gear shafts Mount stop disk 16x26x1 mm on the main shaft Fix the spacing washer 15x20x0 5 mm to the shift drum with a little grease ASS the engine housing Remove engine fastener from engine work stand Make sure that both fitting collars are in place in the right housing half and that the stop disk on the main shaft and the spacing washer are mounted on the shift drum Apply light coat of grease to sealing surfaces of the housing and position new gasket Grease shaft seal rings in left hand half and place left hand half in position Position bolts and tighten with 8 Nm Fix engine in work stand M6x40 6 40 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 6 4 Mounting the shift mechanism Insert the locking spring into the housing as indicated in the illustration Mount the locking lever with the roll facing the engine case preload and mount the circlip with the sharp edge facing up Push the locking lever backwards with a screwdriver and mount the shift drum locating device on the shift roller Degrease and apply Loctite 243 to the thread of bolt O and use the bolt to fasten the shift drum locating device to 10 Nm Grease the shaft seal ring of the shift shaft Carefully grea
40. haft detach the ball socket from the adjusting shaft and pull the adjusting shaft O out of the housing Remove collar bolts and clutch cover including gasket NOTE The water pump cover the outer cover and the cover lid do not need to be removed The water pump and the centrifugal timer remain in the clutch cover Only the outer cover Q needs to be removed to work on the clutch Art Nr 3 206 020 E Repair manual KTM 85 5 105 SX 4 4 Dismounting the clutch Loosen collar bolts in diagonally opposite sequence to prevent wedging of discs as springs expand Remove collar bolts springs and spring retainers Take pressure cap and disc package out of outer clutch hub Remove the pressure piece and the axial needle bearing from the main shaft NOTE The washer on the axial needle bearing may adhere to the pressure cap Release the lock washer of the inner clutch hub Connect clutch holder 470 29 003 000 to inner clutch hub and loosen hexagon nut see illustration Remove clutch holder Remove the driver and the outer clutch hub including the bushing and the stop disk from the main shaft Dismounting of the primary drive Hold the primary pinion with the gear segment 470 29 003 000 9 see illustration Loosen the HH bolt and remove the primary gear NOTE The primary gear and the outer clutch hub belong together Always replace both t
41. hand housing half in the engine work stand Crankshaft Insert crankshaft from above through grooved ball bearing and push carefully as far as stop CAUTION WHEN PUSHING IN CRANKSHAFT MAKE SURE CONROD IS FACING CYLINDER Transmission Oil driving pin for the shift forks and mount Fix the lower stop disc on the countershaft with a small amount of grease Mount drive shaft together with countershaft and insert them into the bearings as far as they will go Oil shift forks prior to mounting Shift fork with the shorter shift dog belongs to the main shaft Mount the two other shift forks at the countershaft using the marks applied before disassembly for better orientation CAUTION ALL OF THE SHIFT FORKS ARE DIFFERENT SO GO BY THE MARKS MADE DURING DEMOUNTING WHEN YOU MOUNT THEM AGAIN NOTE If you forgot to make a mark before disassembling mount the shift forks at the countershaft so that the greatest distance is between the driving pins Fit the shift forks in the sliding gears and insert the shift drum and the spacing washer 25x32x0 5 mm in the grooved ball bearing Attach the shift forks to the shift roller CAUTION WHEN INSERTING THE SHIFT FORKS SURE THE DRIVING PINS DO NOT FALL OUT OF THE SHIFT FORKS Fix the 4 pressure springs with ample amounts of grease in the gearshift rails gearshift rails and insert them into the gearshift forks short
42. ignition system Disconnect yellow black coloured cable from CDI and check ignition spark If the spark is O K repair defective part of cable ignition lock or ignition switch Inspect cable connectors Examine ignition system Dismantle and clean carburetor Readjust idle running or replace idle adjusting screw Examine ignition system Overhaul engine Renew filling Clean or renew airfilter Check control flap joint rod and centrifugal timer Blow through fuel pipe and clean carburetor Tighten spark plug Check exhaust system for damage Check and adjust ignition 8 3 TROUBLE CAUSE REMEDY Engine has not enough power Engine revs not high and running with four stroke cycle High rpm misfiring Engine spluters into the carburetor Engine overheating Reed paddles tensionless or damaged surface of reed valve housing damaged Wear Carburetor overflows if level adjust too high float needle seating 15 dirty or enlarged Loose carburetor jets Incorrect heat range spark plug or low quality spark plug Incorrect or connector spark faulty plug Loose corroded or non conductive ignition socket connector Lack of fuel Spark plug with incorrect heat value Ignition by incandescence Engine takes air out of control Insufficient system liquid in cooling Cooling system not insufficiently bleeded Radiator fins clogged Frothing in cooling system Pinched or kinked water hoses Incorrec
43. l exhaust control components check for signs of wear and damage Bearing sleeves Check bearing sleeves of the control for play and easy operation Control flap O Clean the control flap The control flap must not graze inside the exhaust port Check the silicone O ring in the closing cover and the control O for wear and replace if necessary Pr eassembling the control flap and the cylinder Mount the silicone O ring 8 03x1 78 O on the control flap and grease Push the bearing sleeve onto the right side with the collar facing outwards Fasten the driving disk with the bolt facing outwards and the stop plate O with the stop facing inwards with the bolt Do not tighten yet since this bolt will also be used to adjust the exhaust control measurement Z Position the bearing sleeve with the collar facing outwards and mount the control lever with the ball head facing outwards Mount the overload spring with the long shank facing downwards Apply Loctite 243 to the thread of the AH bolt and screw in the bolt and the spring sleeve several turns Attach the short shank of the overload spring to the cylindrical pin and tighten the AH bolt Push the bearing sleeve onto the left side with the collar facing outwards Insert the preassembled control flap and closing cover including the O ring 12x2 in the cylinder Apply a thin layer of silicone to the sealing areas and mount the flange
44. nd carefully mount the preassembled clutch cover Turn the crankshaft slightly to allow the centrifugal timer to engage in the primary pinion Fit collar bolts see sketch for bolt lengths and tighten with 8 Nm Then check easy running of all shafts NOTE If you cannot mount the clutch cover check whether the kickstarter spring and the shift shaft are in the right position Position the linkage with the counternut facing up insert the adjusting shaft with the lever facing down and press the ball socket on the ball of the lever see illustration Mount the locking screw and the gasket Slide the sealing element into area Finally check the lever for smooth operation by hand Mounting piston and cylinder Before assembly oil all parts thoroughly at the sliding points nsert needle bearing in conrod eye mount piston arrow on piston head shows direction for exhaust duct Mount piston pin and wire circlips with open side showing downwards see sketch Mount cylinder base gaskets Place the piston on a self made wooden stand and adjust the piston ring Place on preassembled cylinder remove wooden stand and tighten cylinder down crosswise using two nuts Art Nr 3 206 020 E Repair manual KTM 85 5 105 SX 6 8 Adjusting dimension X Dimension X is the dimension from upper edge of piston to upper edge of cylinder with cylinder u
45. nd right in both cases as far as it will go This must not cause any changes in idling speed Otherwise you will have to increase the backlash of the throttle cable Art Nr 3 206 020 E Repair manual 85 SX 105 SX DISASSEMBLING THE ENGINE INDEX CLAMP THE ENGINE INTO THE MOUNTING RACK REMOVING OF KICKSTARTER 4 2 DRAINING GEAR QIL on in une ret ner ensure 4 2 DISMOUNTING OF SPROCKET AND SHIFT LEVER 4 2 DISMOUNTING OF ZYLINDER HEAD CYLINDER AND PISTON 4 2 DISMOUNTING OF CLUTCH COVER 4 3 DISMOUNTING THE CLUTCH 4 4 DISMOUNTING OF THE PRIMARY DRIVE 4 4 DISMOUNTING THE KICKSTARTER UNIT 4 9 DISMOUNTING THE SHIFT MECHANISM 4 9 DISMOUNTING THE IGNITION 4 6 DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING 4 7 PARTING OF ENGINE HOUSING HALVES 4 7 DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION 4 7 DISMOUNTING OF THE CRANKSHAFT 4 8 4 1 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 4 2 Clean the engine thoroughly Clamp the engine into the workstand Remove the kickstarter Draining gear oil NOTE Drain the gear oil in a warm condition before the
46. nder low tension and piston in TDC position The dimension X should be adjusted extremely carefully by inserting cylinder base gaskets of suitable thicknesses CAUTION IF THE DIMENSION X IS TOO LARGE THE COMPRESSION RATIO WILL BE REDUCED AND THE ENGINE LOOSES POWER ON THE OTHER HAND IF THE DIMENSION X IS TOO SMALL THE ENGINE WILL PING AND OVERHEAT Move the piston to TDC and apply the adjusting plate 470 29 006 000 85 SX or 475 29 006 000 105 SX see illustration Use a feeler gauge to measure the gap between the upper edge of the piston or cylinder and the master gauge correctly adjusted the master gauge will fit flush against the upper edge of the piston and cylinder Correct by adding or removing cylinder base gaskets CAUTION THE PISTON MUST NOT PROTRUDE BEYOND THE CYLINDER S UPPER EDGE Mount the 2 remaining collar nuts at the cylinder base and tighten each of the 4 collar nuts to 30 Nm Adjusting control flap dimension Z NOTE Dimension Z is the distance from the lower edge of the control flap to the upper edge of the cylinder as measured in the centre of the exhaust port with the adjusting plate 470 29 006 000 85 SX or 475 29 006 000 105 SX ES 5 85 SX dimension Z 32 mm 105 SX dimension 2 31 mm f 2 Z Loosen the screw on the stop plate and apply Loctite 243 to the thread Mount the screw again but do not tighten ye
47. ngly when you remove them 3 206 020 E Art Nr Repair manual KTM 85 SX 105 SX 4 8 Take the pressure springs out of the engine case Pull the drive shaft together with the countershaft out of the bearing seats Remove 1 gear idler gear with needle cage and the two stop discs from the engine case Dismounting the crankshaft Pull crankshaft from the bearing seat if necessary use a plastic hammer and tap carefully on the crankshaft journal Clean all parts and check for wear replace if necessary NOTE When an engine is completely overhauled it is recommended that all gaskets shaft seal rings and O rings are renewed Art Nr 3 206 020 E Repair manual 85 SX 105 SX 9 1 SERVICING ON INDIVIDUAL COMPONENTS INDEX WORKING ON THE RIGHT HAND HOUSING HALF 9 2 WORKING ON THE LEFT HAND HOUSING HALF 9 3 GRANKSHARE wick 2 3 3 9 an nn 9 4 PISTON roads shea a ee 9 4 PISTON RING END GAP usus kx x tans e ia 9 4 CHECKING CYLINDER FOR WEAR 9 9 RECOATED CYLINDER 255554 panne eee eae E O a A 9 9 NIKASIL COATING OF CYLINDER 9 9 CYLINDER EXHAUST CONTROL SYSTEM 9 6 PREASSEMBLING THE CONTROL FLAP AND THE CYLINDER 9 6 DISMOUNTING THE CENTRIFUGAL TIMER AND THE WATER PUMP
48. nnect the fuel hose to the carburetor Mount the chain and the chain joint When mounting the chain joint make sure that the closed side of the safety device is facing the moving direction Mount the seat When mounting make sure the locating tab engages in the seat Tighten bolt O A eee the cooling system Pour approx 0 5 litres coolant into the system Remove the bolt on the right radiator Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the bolt so that no more air can enter the right radiator Top up the left radiator until the coolant can be seen approx 10 mm above the radiator fins Total capacity 1 After installing briefly warm up the engine and top up the cooling liquid If the engine is working properly a short careful test ride can be taken After the test ride check the engine and the exhaust system for leaks Adjusting the throttle cable There must always be a 3 5 mm play in the throttle cable To check this move back the protective cover on the throttle grip You must be able to lift the outer covering of the cable 3 5 mm from the adjusting screw until resistance is felt To adjust loosen the counternut and turn the adjusting screw accordingly Finally tighten the counternut and slide the protective cover back on To check the correctness of this setting start the engine turn the handlebar left a
49. nt NGK BR 10 ECMVX 0 60 mm flat slide carburetor carburetor see table 1 liter mixture 50 antifreeze 50 water at least 25 C 13 F Air filter wet foam type air filter insert BASIC CARBURETOR SETTING Carburetor Keihin PWK 28 Main jet 118 Needle jet 2 6 Jet needle N5HG Needle position from top Throttle valve 3 5 starting jet 62 Air adjustment screw open 1 5 VERGASERREGULIERUNG CARBURETOR SETTING 85 SX 2005 KEIHIN PWK 28 MEERESHOHE TEMPERATUR 20 C bis 7 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C ALTIDUDE TEMPERATURE 2 F to 20 F 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 3000 m ASO 1 5 1 75 225 2 5 10000 ft J 45 42 38 38 NEEDLE N5HG N5HH N5HH N5HH 2301 m POS 3 1 7501 ft 118 115 115 115 2300 m 7500 ft NEEDLE 1501 m POS 5001 ft MJ 1500 m ASO 5000 ft IJ NEEDLE 751m POS 2901 TI 750 m 2500 ft NEEDLE 301m POS 1001 ft MJ 300 m ASO 1000 ft IJ NEEDLE Meeresniveau POS Sea level MJ LSO Luftregulierschraube offen 1 5 screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se S Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY USE Kraftstoff Super Bleifrei ROZ 95 Fuel unleaded fuel with at least RON 95 USA Premium RON 91 Art Nr 3 206 0
50. nt the engine sprocket with the collar facing inwards on the countershaft and fix with circlip O Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 6 12 Mounting the kickstarter and shift lever Mount the kickstarter Apply Loctite 243 to the kickstarter bolt and tighten to 12 Nm Mount the shift lever Apply Loctite 243 to the shift lever bolt and tighten to 12 Nm Operate the kickstarter a few times and check if the engine turns freely Oil the push rod and insert in the main shaft together with the ball 2 6 mm Mount oil drain plug Fill in transmission oil NOTE The transmission oil should be filled in only after the engine has been mounted Otherwise a part of the transmission oil would leak out through the drive shaft Remove the filler plug and add 0 50 gear oil e g Motorex Topspeed 4T 15W50 Mount the filler plug and check the engine for leaks CAUTION NOT ENOUGH OIL OR A POOR OIL QUALITY LEAD TO PREMATURE WEAR OF THE TRANSMISSION THEREFORE USE ONLY HIGH QUALITY OILS E G MOTOREX ToPsPEED 4T 15W50 Quantity of oil 0 50 liter Checking gear oil level To check the gear oil warm up the engine to operating temperature with a low load and place the motorcycle on an even surface Remove the oil drain plug and allow the gear oil to drain into a vessel Clean the sealing area mount the oil drain plug and gasket and tighten to 15 Nm Remove the
51. of contents 150x297 mm into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page Example page no 3 5 3 chapter 3 5 page 5 All pages with a page number that begins with the digit 3 for example must be put under the index heading Chapter 3 Index sheets that have not been marked with a certain chapter are for your personal convenience The respective headings can be entered in the list of contents Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX EXPLANATION UPDATING This repair manual contains the following supplements 3 206 008 E Repair Manual 85 SX Basicversion Modelyear 2004 06 2003 3 206 020 E Updating of Rep Manual 3 206 008 E Modelyear 2005 07 2004 from engine number B85 500 001 Modification Updating 105 SX Technical Specification Special Tools Periodic Maintenance Schedule Edition 07 2004 INTRODUCTION This repair manual offers extensiv repair instructions and is an up to date version that describes the latest models of the series However the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual A description of general working modes common in work shops has not been includ
52. ogether Pull the woodruff key and the distance sleeve including the O ring behind the distance sleeve off of the crankshaft Dismounting the kickstarter unit Remove the circlip and the stop disk take off the kickstarter idler gear and the stop disk behind the idler gear Carefully unscrew the collar bolt O relieve the kickstarter spring and remove the kickstarter shaft from the engine case Take care of the stop disc which could stay in the housing A WARNING A CAREFULLY RELEASE THE KICKSTARTER SPRING DANGER OF INJURY Dismounting the shift mechanism Press back the shift rail 8 until it no longer engages in the driver for the shaft roller while you pull the shift shaft out of the housing NOTE Watch the stop disc which remains in the housing Loosen the collar bolt and remove the shift lock To remove slightly press the locking lever towards the rear NOTE Disassemble locating lever only if the engine case must be replaced To disassemble remove the circlip and take off the locking lever and the spring Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 4 6 Dismounting the ignition Undo the 3 bolts and remove the ignition cover together with the gasket Apply the holding spanner 546 29 012 000 and undo the collar nut Remove the collar nut and the locking cant ring Put the protection cover 510 12 016 000 on the crankshaft thread twist in
53. oil filler screw and add 0 5 liters of gear oil e g Motorex Topspeed AT 15W50 Mount the oil filler screw and check the engine for leaks NOTE Due to a change in the fluid capacities the inspection screw can no longer be used f the gear oil is still clean you can continue to use it up to your next service Art Nr 3 206 020 E Repair manual 85 5 105 SX INDEX RESISTOR VALUES OF THE IGNITION SYSTEM STATOR 1 2 IGNITION COIL s mE ROS E san 1 2 MEASURING STATIC IGNITION VALUES WITH PEAK VOLTAGE ADAPTER 1 3 SPARK PLUG xd Reg s n 1 3 1 1 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 1 2 Resistor values of the ignition system Stator Unplug the connector on the ignition stator and measure the resistance of the stator coils at 20 C using a digital multimeter Pulse generator between the white red and white blue cable Multimeter display 3100 60 Q CDI voltage supply between the green blue and black cable Multimeter display 55 0 10 Q Capacitor charging coil between the black red and green white cable Multimeter display 900 180 Q NOTE the stator does not need to be removed to measure Ignition coil Unscrew the spark plug connector and disconnect the cable for the primary drive Measure the resistance on the primary side of the ignition coil between the primary drive plug
54. okes when the throttle is fully opened and develops its full power not smoothly but Ep main jet suddenly at high engine speeds the mixture to the carburetor will be jet needle too rich the fuel level too high or the float needle is leaking Part throttle range C Jet needle Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle J p idling jet setting is controlled by the idling setting in the lower range and by the IN Ww gt throttle valve E in a If the A i OO or A gt with reduced power when it is accelerated wi e throttle partly open KUALA the jet needle must be lowered by one notch If the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer idling jet Full throttle range D Operation with the throttle fully open flat out This range is influenced by the main jet and the jet needle If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings after a short distance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one
55. on of shift roller in grooved ball bearings Slide plate O 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 O Check the preload of the pressure spring for the slide plate Grooved ball bearings O 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 Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 9 12 Transmission Secure mainshaft or countershaft in the vice using soft jaw covers Remove gears and check the following for wear Needle bearing Mainshaft and countershaft pivot points including idler gears Shift dogs and gear wheels Tooth faces of all gears Tooth profile of mainshaft and countershaft and correspondending gears Easy operation of gear change Check the friction bearings in the idler gears for score marks and a flawless condition Carefully clean components and replace damaged components NOTE Always
56. otches in the contact surface facing down and slip on the stop disk 15x25x1 Finally check all of the gears for smooth operation Ir um Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX LOCTITE 243 Checking the kickstarter for wear Take all components off the kickstarter shaft and clean them Kickstarter gear Check the toothing for wear and the bearing for clearance Kickstarter idler gear O 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 amp Check the inclined surface and the toothings for wear Kickstarter shaft O Check bearing positions and toothings for wear and damage Check the oil bore for the kickstarter gear for unobstructed passage Ratchet gear spring 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 O with the toothed end facing up in the vise use protective jaws Mount the circlip O Slide the kickstarter ratchet gear and the ratchet gear spring on the kickstarter shaft so that the nose is located on the left side of the hole see illustration Slip on the kickstarter pinion with the toothing facing down Fix the kickstarter spring in the hole in the kickstarter shaft and sli
57. r 2 5 CLEANING Clean your motorcycle regularly in order to keep its painted finish looking shiny and new The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge The hard dirt can be removed before with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET OTHERWISE THE WATER MIGHT RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE MAILFUNCTIONS LEAD TO THE PREMATURE DESTRUCTION OF THESE PARTS You should use commercially available detergents to clean the motorcycle Heavily soiled parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached its operating temperature and also operate the brakes The heat also causes the water at the inaccessible parts of the engine and the brakes to evaporate Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Also treat the chain with a chain spray To prevent failur
58. sc clutch in oil bath hydraulic operated Motorex Kupplungs Fluid 75 Transmission 6 speed claw actuated Gear ratio 1 gear 11 29 2 gear 14 28 3 gear 16 26 4 gear 19 26 5 gear 21 25 6 gear 20 21 Transmission oil 0 50 liter engine oil Motorex Topspeed 4T 15W50 Ignition system Moric Digital 2M1 Spark plug NGK BR 10 ECMVX 0 60 mm Art Nr 3 206 020 E Electrode gap Carburetor flat slide carburetor carburetor see table 1 liter mixture coolant water 2 1 at least 25 C 13 Air filter wet foam type air filter insert BASIC CARBURETOR SETTING Carburetor Keihin PWK 28 Needle jet 2 6 Idling jet 45 Jet needle N5HG Needle position from top Throttle valve 35 Repair manual KTM 85 SX 105 SX Starting jet 62 Air adjustment screw open 1 5 Frame TECHNICAL SPECIFICATIONS CHASSIS 85 SX 2004 Central chrome moly steel frame Fork telescopic fork White Power 43 MXMA Wheel travel front rear 2 5 mm 300 mm Rear suspension WP PDS 4618 Progressive Damping System shock absorber Front brake Disc brake 0 220 mm 4 piston Rear brake Disc brake 200 mm 4 piston Tires front 70 100 17 Pirelli MT 32A 70 100 19 Pirelli MT 32A Tires rear 90 100 14 Pirelli MT 320 90 100 16 Pirelli MT 320 Air pressure 1 0 bar Fuel tank capacity 5 1 liter Final drive ratio Chain 1 2 x 5 16
59. se the preassembled shift shaft and carefully insert it together with the stop disk 15x25x0 5 mm in the engine case Push back the shift rail O and insert the shift shaft in the engine case all the way up to the stop Mount the foot shift lever and shift through all gears When shifting through the gears turn the countershaft Then remove the foot shift lever Mounting kickstarter Oil the bearing bore for the kickstarter shaft Insert the preassembled kickstarter shaft and the stop disk 15x25x1 mm in the bearing bore so that the nose Q on the ratchet gear spring is located between the two bars and the nose on the ratchet gear is behind the stop Q Apply Loctite 243 to the thread of the bolt M5x25 mm Mount the spring bushing 6 preload the starter spring and put into place see illustration and tighten the bolt to 6 Nm Oil the bearing position of the starter idler and slide on the stop disk 15x25x0 5 mm Mount the starter idler on the bearing pin with the high collar facing the engine case Slip on the stop disk 15x25x0 5 mm and mount the circlip with the sharp edge facing outwards Mount primary drive and clutch Grease crankshaft seal ring Slide the oiled O ring 18 77 x 1 78 mm on the crankshaft and slip on the distance sleeve Mount the woodruff key and slide the primary pinion on the crankshaft Apply the special tool 470 29 003 000 as shown D
60. shift drum on a flat wooden surface Insert a new grooved ball bearing and press in gently up to the stop Needle bushing of shift shaft O Remove shaft seal ring and press old needle bushing inwards Press in new needle bushing from the outside to the collar O Crankshaft seal ring O Press in a new shaft seal ring from the outside until the sealing lip is flush with the inner surface Counter shaft seal ring Press in a new shaft seal ring until the sealing lip is flush with the inner surface Shift shaft seal ring Press in a new shaft seal ring up to the stop with the sealing lip on the inside When housing half has cooled off check to see that the bearings are tight Finally check clear passage of the crankshaft roller bearing lubrication bore Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX 5 4 Crankshaft When replacing the roller bearing the inner crankshaft ring must also be renewed Heat special tool 584 29 037 031 on a heating pad up to approx 150 C and slip it on the inner ring immediately Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft To mount the new inner ring heat the special tool again to approx 150 C engage the inner ring and slip it on the crankshaft journal immediately Make sure the inner ring is pushed back to the stop CAUTION NEVER CLAMP THE CRANKSHAFT WITH A STUD OR WEB IN THE VICE
61. t Fold the control flap up and hold the adjusting plate 470 29 006 000 85 SX or 475 29 006 000 105 SX in the cylinder as shown in the drawing Fold the control flap back down and up against the setting gauge Turn the stop plate until it rests against the edge of the stop 6 Fix the stop plate by tightening the screw After the screw is tightened check dimension Z again and correct if necessary Press the control flap all the way down and press the ball socket O onto the ball of the control lever NOTE When you press on the ball socket make sure there is no stress towards the top or bottom Adjust linkage length if necessary To do so loosen counter nut and turn ball socket accordingly Retighten counter nut Mount the control cover Q together with the gasket and fix with 3 bolts 6 10 Mounting the ignition Degrease the crankshaft and insert the woodruff key in the crankshaft Fix the stator with 3 collar bolts M5x16 but do not tighten yet Mount the cable guide in the housing opening Mount the rotor on the crankshaft Then mount the spring ring with the hexagon nut Insert the holding tool 546 29 012 000 into the two bores and tighten the hexagon nut with 60 Nm Adjusting the ignition Set the piston to TDC and hold the adjusting plate 470 29 006 000 85 SX or 475 29 006 000 105 SX against the upper edge of the cylinder
62. t ignition timing because of loose stator bolts Incorrect dimension Replace reed paddles or reed valve housing Overhaul engine Clean carburetor if necessary replace float needle and adjust level Tighten jets Refer to technical data section Test and or replace spark plug connectors correct type Check and seal with silicon Clean fuel pipes examine tank aeration and clean Fit correct spark plug Check intake flange and carburettor if firmly setted Top up coolant and bleed cooling system check cooling system for leaks Bleed cooling system see operating instructions Clean radiator fins with water jet Renew coolant using branded anti freeze anti corrosive Replace with correct routed hoses Readjust to correct ignition timing specifications secure bolts properly with Loctite 243 Measure and adjust to correct specification Emission of white smoke Cylinder head or O ring of cylinder Check cylinder head replace O ring steam head gasket leaks Water in transmission oil Shaft seal ring of the water pump Replace shaft seal ring of the water pump defect Excessive oil from escapes transmission breather tube Excessive oil transmission quantity in Correct transmission oil level Art Nr 3 206 020 E Repair manual KTM 85 SX 105 SX TECHNICAL SPECIFICATIONS INDEX 85 SX MODEL 2004 ENGINE errors UT CARBURETOR ua nn raras arrasados CHASSIS
63. the flywheel extractor 546 29 009 044 and remove the flywheel Undo the 3 bolts and remove the stator together with the base plate Dismounting of intake flange and reed valve housing Remove the 4 collar bolts Remove the intake flange and the reed valve housing together with the gasket Parting of engine housing halves Top ignition gear upwards and remove all 10 housing bolts Loosen the 2 engine fixtures on the engine work stand Lift left hand housing half with suitable tools by on the bosses provided or part with a few light plastic mallet blows against the countershaft from the right hand housing half CAUTION LEVERING APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED SINCE THE SEAL FACES ARE EASILY DAMAGED Dismounting of gearshift mechanism and transmission Remove the stop disk from the main shaft Pull the 2 pressure springs out of the shift rails Remove the stop disk from the shift drum NOTE Pay attention to the stop disks 9 and O when you separate the engine case they may adhere to the inside of the case Pull out the shift rails and swing the shift forks aside Pull the shift drum and stop disk out of the bearing seat Remove the shift forks NOTE When dismounting pay attention to the needle rollers which could stay behind in the shift drum Since the shift forks differ from each other be sure to mark them accordi
64. water pump Use a self made supporting plate to support the puller to avoid damage to the housing see illustration Pull out the bearing using a 5 8 mm inside puller 151 12 018 200 151 12 017 000 Press in new grooved ball bearing to the stop Crankshaft seal ring O Press in new shaft seal ring from the outside with sealing lip facing inward until flush Finally check clear passage of the crankshaft ball bearing lubrication bore Working on the left hand housing half Remove all shaft seal rings and use an oven to heat the casing half to approx 150 C The bearings usually fall out of their seat of their own accord by knocking the housing half on a plane piece of wood when the housing has a temperature of 150 C Crankshaft roller bearing Press old roller bearing inwards press in new ball bearing to the stop with the open side of ball cage downwards outside The inner ring on the crankshaft must also be renewed see paragraph about crankshaft Needle bearing of drive shaft O Press old grooved ball bearing inward press new grooved ball bearing from the inside up to the stop Grooved ball bearing of countershaft Press old ball bearing inwards press in new ball bearing to the stop from inside Grooved ball bearing of shift roller Heat the shift drum to approx 150 At this temperature the grooved ball bearing will automatically fall out of the bearing seat If necessary tap the

Download Pdf Manuals

Related Search

REPAIRMANUAL2004 2005

REPAIRMANUAL2004-2005

Contents

Download Pdf Manuals

Related Search

Related Contents