2004 KTM 85 SX Repair Manual – PDF DOWNLOAD

Description

2004 KTM 85 SX Repair Manual – PDF DOWNLOAD

DESCRIPTION:

2004 KTM 85 SX Repair Manual – PDF DOWNLOAD

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 included. 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.

TABLE OF CONTENTS:

2004 KTM 85 SX Repair Manual – PDF DOWNLOAD

HOME…………………………………………………………………. 0
NOTES AND PREFACE………………………………………………….. 1
Title page and file spine……………………………………….. 1
Important information…………………………………………… 7
Explanation update……………………………………………… 9
Introduction……………………………………………………11
Reply fax for repair manuals……………………………………..13
TABLE OF CONTENTS………………………………………………….. 5
SERVICE-INFORMATIONS……………………………………………. 1
GENERAL INFORMATION……………………………………………..15
CARBURETOR ADJUSTMENT………………………………………..17
BLEEDING OF THE HYDRAULIC CLUTCH………………………………18
SPECIAL TOOLS……………………………………………….19
CLEANING……………………………………………………20
STORAGE…………………………………………………….20
REMOVING AND REFITTING ENGINE…………………………………….21
DISMOUNTING THE ENGINE……………………………………….23
MOUNTING THE ENGINE………………………………………….26
BLEEDING THE COOLING SYSTEM…………………………………..28
ADJUSTING THE THROTTLE CABLE………………………………….28
DISASSEMBLING THE ENGINE…………………………………………29
CLAMP THE ENGINE INTO THE MOUNTING RACK, REMOVING OF KICKSTARTER….31
DRAINING GEAR OIL……………………………………………31
DISMOUNTING OF SPROCKET AND SHIFT LEVER………………………..31
DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON……………….31
DISMOUNTING OF CLUTCH COVER…………………………………..32
DISMOUNTING THE CLUTCH……………………………………….33
DISMOUNTING OF THE PRIMARY DRIVE………………………………33
DISMOUNTING THE KICKSTARTER UNIT………………………………34
DISMOUNTING THE SHIFT MECHANISM……………………………….34
DISMOUNTING THE IGNITION……………………………………..35
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING……………..36
PARTING OF ENGINE HOUSING HALVES………………………………36
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION……………..36
DISMOUNTING OF THE CRANKSHAFT…………………………………37
SERVICING INDIVIDUAL COMPONENTS…………………………………..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
CHECKING CYLINDER FOR WEAR……………………………………44
RECOATED CYLINDER……………………………………………44
NIKASIL COATING OF 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
DISASSEMBLING THE SHIFTING SHAFT………………………………50
SHIFTING MECHANISM – CHECKING PARTS FOR WEAR……………………50
PREASSEMBLING THE SHIFTING SHAFT………………………………50
ASSEMBLY MAINSHAFT…………………………………………..51
ASSEMBLY COUNTERSHAFT………………………………………..52
CHECKING THE KICKSTARTER FOR WEAR……………………………..53
PREASSEMBLING THE KICKSTARTER SHAFT……………………………53
ASSEMBLING THE ENGINE……………………………………………55
CRANKSHAFT………………………………………………….57
TRANSMISSION………………………………………………..57
ASSEMBLING THE ENGINE HOUSING…………………………………58
MOUNTING 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 REED VALVE HOUSING AND INTAKE FLANGE…………………..66
MOUNTING ENGINE SPROCKET……………………………………..66
MOUNTING THE KICKSTARTER AND SHIFT LEVER……………………….67
FILL IN TRANSMISSION OIL……………………………………..67
CHECKING GEAR OIL LEVEL………………………………………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………………………………………………….72
TROUBLE SHOOTING………………………………………………..73
TROUBLE SHOOTING 85 SX……………………………………….75
TECHNICAL SPECIFICATIONS…………………………………………77
ENGINE……………………………………………………..79
CARBURETOR………………………………………………….79
CHASSIS…………………………………………………….80
STANDARD ADJUSTMENT SHOCK ABSORBER / FORK………………………80
TOLERANCES AND FITTING CLEARANCES……………………………..81
TIGHTENING TORQUES ENGINE…………………………………….81
TIGHTENING TORQUES CHASSIS……………………………………81
PERIODIC MAINTENANCE SCHEDULE…………………………………….83
LUBRICATION AND MAINTENANCE SCHEDULE 85 SX……………………..84
WIRING DIAGRAMS…………………………………………………87
WIRING DIAGRAM 85 SX…………………………………………88

IMAGES PREVIEW OF THE MANUAL:

2004 KTM 85 SX REPAIR MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V