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KTM 85 SX 2004 Repair Manual Download Page 49

5-10

Repair manual  KTM  85 SX

Art No  3.206.008-E

Replace outer clutch hub 

– Drill open the clutch rivets 

1

in area of retaining bracket 

2

and

remove parts.

– Check 6 absorbing elements 

3

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 

A

rest on the rivets 

B

.

– Apply the special tool 470.29.027.000 as shown, screw together and

clinch the rivets with the press.

1

2

A

B

3

Summary of Contents for 85 SX 2004

Page 1: ...85 SX REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN ART NR 3 206 008 E REPAIRMANUAL2004 ...

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Page 3: ...REPAIRMANUAL2004 85 SX KTM Group Partner ...

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Page 5: ...ATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS 12 13 14 15 16 ...

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Page 7: ...list 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 begin...

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Page 9: ...Repair manual KTM 85 SX Art No 3 206 008 E EXPLANATION UPDATING Edition 06 2003 This repair manual contains the following supplements 3 206 008 E Repair Manual 85 SX Basicversion Modelyear 2004 06 2003 ...

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Page 11: ...e repair work WARNING STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS 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 th...

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Page 13: ...NOTE to table Enter the complete item no for the repair manual in column 1 e g 3 206 008 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 ...

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Page 15: ...GENERAL INFORMATION Repair manual KTM 85 SX Art No 3 206 008 E CARBURETOR ADJUSTMENT 2 2 BLEEDING OF THE HYDRAULIC CLUTCH 2 3 SPECIAL TOOLS 2 4 CLEANING 2 5 STORAGE 2 5 INDEX 2 1 2 ...

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Page 17: ...ttle valve This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 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 ...

Page 18: ...re 3 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 CLU...

Page 19: ...85 Loctite 243 blu 6 cm3 4 510 12 011 000 Circlip plier 5 503 29 050 000 Vent syringe for hydraulic clutch 6 546 29 009 044 Magneto extractor M 27x1 7 510 12 016 000 Protection cap 8 151 12 018 200 Internal bearing puller 5 7 mm 9 546 29 012 100 Holding spanner for flywheel 10 151 12 017 000 Bearing puller 11 470 29 006 000 Adjusting plate 12 584 29 037 031 Mounting tool inner ring NJ207 13 470 29...

Page 20: ...bserve 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 fi...

Page 21: ...SMOUNTING AND MOUNTING THE ENGINE Repair manual KTM 85 SX Art No 3 206 008 E DISMOUNTING THE ENGINE 3 2 MOUNTING THE ENGINE 3 5 BLEEDING THE COOLING SYSTEM 3 7 ADJUSTING THE THROTTLE CABLE 3 7 INDEX 3 1 3 ...

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Page 23: ...of burns Jack the motorcycle up on a stable supporting device Remove the bolt 1 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 2 and remove Lift of tank together with spoilers Unhook the two springs 3 of the exhaust pipe Remove the bolt of the front exhaust bracket 4...

Page 24: ... into an appropriate basin Put the carburetor into a clean cloth and lay it on the air filter box Remove the radiator cap Remove drain bolt 4 at the water pump cover and drain cooling liquid Loosen hose clamp 5 and disconnect the radiator hose Unscrew the three bolts on the clutch slave cylinders and the bolt 6 on the chainguard Remove the chainguard and tilt the clutch slave cylinder 7 to the sid...

Page 25: ...r 2 Loosen the bolt 3 on the radiator mounting and pull the wiring harness through Loosen hose clamp 4 and disconnect radiator hose at the cylinder head Remove the two engine fixing bolts 5 and the hexagon nut 6 Dismount the swing arm pivot and pull the swing arm towards the rear Lift the engine out of the frame 1 2 3 4 5 5 6 ...

Page 26: ... with the bolt 5 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 6 Mount the clutch slave cylinder and the chainguard and tighten the three bolts to 10 Nm Tighten the bolt 7 NOTE Two bolts M6x16 are used in position A one bolt M6x20 in position B Mount the bolt 8 of the water pump cover with a new...

Page 27: ...k the spring 4 Correctly position the tank and mount the bolt 5 with the tank roller tighten the bolt to 10 Nm Connect 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 6 1 2 3 4 4...

Page 28: ... 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 2 on the throttle grip You must be able to lift the outer covering of the cable 3 5 mm from the adjusting screw 3 until resistance is felt To adjust loosen the counternut 4 and turn the adjusting sc...

Page 29: ...ER 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 5 DISMOUNTING THE SHIFT MECHANISM 4 5 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 CR...

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Page 31: ...d shift lever Remove the circlip 2 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 3 and remove the shift lever Remove the push rod 4 and the ball positioned behind the push rod from the main shaft Dismounting of cylinder head cylinder and piston Unscrew the 6 collar bolts 5 and remove cylinder head...

Page 32: ...AUTION 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 shaft 3 detach the ball socket from the adjusting shaft and pull the adjusting shaft 4 out of the housing Remove collar bolts and clutch cover including gasket NOTE The water pump cover 5 the outer cover 6 ...

Page 33: ... needle bearing may adhere to the pressure cap Release the lock washer of the inner clutch hub Connect clutch holder 470 29 003 000 4 to inner clutch hub and loosen hexagon nut see illustration Remove clutch holder Remove the driver and the outer clutch hub including the bushing 5 and the stop disk 6 from the main shaft Dismounting of the primary drive Hold the primary pinion with the gear segment...

Page 34: ... stop disc which could stay in the housing WARNING CAREFULLY RELEASE THE KICKSTARTER SPRING DANGER OF INJURY Dismounting the shift mechanism Press back the shift rail 5 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 slight...

Page 35: ...the gasket Apply the holding spanner 546 29 012 000 1 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 the flywheel extractor 546 29 009 044 and remove the flywheel Undo the 3 bolts 2 and remove the stator together with the base plate 2 1 ...

Page 36: ... SIMILAR TOOL MUST BE AVOIDED SINCE THE SEAL FACES ARE EASILY DAMAGED Dismounting of gearshift mechanism and transmission Remove the stop disk 2 from the main shaft Pull the 2 pressure springs 3 out of the shift rails Remove the stop disk 4 from the shift drum NOTE Pay attention to the stop disks 2 and 4 when you separate the engine case they may adhere to the inside of the case Pull out the shift...

Page 37: ...er gear 2 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 1 1 2 ...

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Page 39: ...4 PREASSEMBLING THE KICKSTARTER SHAFT 5 14 INDEX 5 1 5 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 ...

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Page 41: ...e Press in a new grooved ball bearing from the inside to the stop Needle bushing of the shift shaft 5 Press old needle bushing inwards press in new needle bushing flush from the outside Grooved ball bearing of centrifugal timer 6 Use a self made supporting plate to support the puller to avoid damage to the housing see illustration Pull out the bearing using a Ø 5 8 mm inside puller 151 12 018 200 ...

Page 42: ...nside Grooved ball bearing of shift roller 4 Heat the shift drum to approx 150 C At this temperature the grooved ball bearing will automatically fall out of the bearing seat If necessary tap the 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 5 Remove shaft seal ring and press old needle bushing inwards Press in...

Page 43: ...iston 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 ...

Page 44: ...ust control components must be removed The intermediate flange 1 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 carb...

Page 45: ...lt 7 Do not tighten yet since this bolt will also be used to adjust the exhaust control measurement Z Position the bearing sleeve 8 with the collar facing outwards and mount the control lever 9 with the ball head facing outwards Mount the overload spring bk with the long shank facing downwards Apply Loctite 243 to the thread of the AH bolt bl and screw in the bolt and the spring sleeve bm several ...

Page 46: ...r adjustments Replacing the grooved ball bearings bk for the water pump and the centrifugal timer bl Remove the shaft seal ring bm 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 ...

Page 47: ...using intake flange NOTE Reed paddles 1 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 2 Check for firm mounting and for signs of damage 1 2 ...

Page 48: ...el discs 5 Must be plane check for mechanical damage Inner clutch hub 6 Check the contact surfaces of the steel disks against the driver Check the driver for mechanical damage or score marks Pressure cap 7 Check contact surfaces A between lining disc and pressure cap for signs of mechanical damage and score marks Outer clutch hub 8 Check start surfaces B of clutch discs on for wear If indentations...

Page 49: ...acket 2 and remove parts Check 6 absorbing elements 3 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 A rest on the rivets B Apply the special tool 470 29 027 000 as shown screw together and clinch the rivets with the press 1 2 A B 3 ...

Page 50: ...de plate 5 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 6 Check the preload of the pressure spring for the slide plate Grooved ball bearings 9 Check grooved ball bearings for easy movement Preassembling the shifting shaft Insert the slide plate into the shift quadrant and slide...

Page 51: ... 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 graphite paste MOS2 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 1 with the shift...

Page 52: ...e than 0 20 mm and must not seize between stop discs Apply graphite paste MOS2 to the idler gears before you mount them Assembly countershaft Fix countershaft in vice with toothed end use covered clamps Oil all parts before assembly Slide on the 2nd idler gear 1 with the collar facing down Mount the circlip 2 21 SW with the sharp edge facing up Slip on the 6th sliding gear 3 with the shift groove ...

Page 53: ...starter gear for unobstructed passage Ratchet gear spring 5 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 4 with the toothed end facing up in the vise use protective jaws Mount the circlip 6 Slide the kickstarter ratchet gear 3 and the ratchet gear spring ...

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Page 55: ...CH DISCS AND PRESSURE CAP 6 6 MOUNTING CLUTCH COVER 6 6 MOUNTING PISTON AND CYLINDER 6 7 ADJUSTING DIMENSION X 6 8 ADJUSTING CONTROL FLAP DIMENSION Z 6 9 MOUNTING THE IGNITION 6 10 ADJUSTING THE IGNITION 6 10 MOUNTING CYLINDER HEAD 6 11 MOUNTING REED VALVE HOUSING AND INTAKE FLANGE 6 11 MOUNTING ENGINE SPROCKET 6 11 MOUNTING THE KICKSTARTER AND SHIFT LEVER 6 12 FILL IN TRANSMISSION OIL 6 12 CHECKI...

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Page 57: ...gs as far as they will go Oil shift forks prior to mounting Shift fork 2 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 di...

Page 58: ... washer 3 15x20x0 5 mm to the shift drum with a little grease Assembling 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 ...

Page 59: ...carefully insert it together with the stop disk 15x25x0 5 mm in the engine case Push back the shift rail 5 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...

Page 60: ...odruff key and slide the primary pinion 2 on the crankshaft Apply the special tool 470 29 003 000 as shown Decrease the HH bolt M10x1 25x20 apply Loctite 243 and tighten to 80 Nm Mount the stop disk 3 20x32x2 mm and the bushing 4 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 5 and tighten hexagon ...

Page 61: ...over 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 A to engage between the two shanks B of the return spring Apply silicone to area C and carefully mount the preassembled clutch cover Turn the crankshaft slightly to allow the centrifu...

Page 62: ...eration by hand Mounting piston and cylinder Before assembly oil all parts thoroughly at the sliding points Insert 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 p...

Page 63: ...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 see illustration Use a feeler gauge to measure the gap between the upper edge of the piston or cylinder and the master gauge If correctly adjusted the master gauge will fit flush against the upper edge of the piston and cylinder Correc...

Page 64: ...ing Fold the control flap back down and up against the setting gauge Turn the stop plate 2 until it rests against the edge of the stop 3 Fix the stop plate by tightening the screw 1 After the screw 1 is tightened check dimension Z again and correct if necessary Press the control flap all the way down and press the ball socket 4 onto the ball of the control lever NOTE When you press on the ball soc...

Page 65: ...he piston to TDC and hold the adjusting plate 470 29 006 000 against the upper edge of the cylinder Turn the rotor in a counterclockwise direction until the upper edge of the piston rests against the setting gauge see drawing Now turn the stator until the two marks 3 coincide CAUTION BEFORE CHECKING THE IGNITION THE DIMENSION X MUST BE ADJUSTED CORRECTLY Tighten the 3 collar bolts on the stator to...

Page 66: ...the total tightening torque of 10 Nm In 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 2 with oil and slide over counter shaft Slide distance bushing 3 in position so that O ring is in correct pos...

Page 67: ... add 0 35 l 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 35 liter Checking gear oil level Allow the engine to warm up park the motorcycle in a horizontal position jack up and wait ...

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Page 69: ...RICAL Repair manual KTM 85 SX Art No 3 206 008 E RESISTOR VALUES OF THE IGNITION SYSTEM STATOR 7 2 IGNITION COIL 7 2 MEASURING STATIC IGNITION VALUES WITH PEAK VOLTAGE ADAPTER 7 3 SPARK PLUG 7 3 INDEX 7 1 7 ...

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Page 71: ...il between the black red and green white cable Multimeter display 900 Ω 180 Ω 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 and the ignition coil ground Multimeter display under 10 Ω at 20º C Measure th...

Page 72: ...k cable disconnect plug 1 Multimeter display 40 volts 5 volts Same measurement with CDI unit connected Multimeter display 35 volts 5 volts Check capacitor charging coil 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 1 Multimeter display 270 volts...

Page 73: ...TROUBLE SHOOTING Repair manual KTM 85 SX Art No 3 206 008 E TROUBLE SHOOTING 85 SX 8 2 INDEX 8 1 8 ...

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Page 75: ...burettor 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 If no spark is produced loosen spark plug ...

Page 76: ...ater hoses Incorrect ignition timing because of loose stator bolts Incorrect dimension X Cylinder head or O ring of cylinder head gasket leaks Shaft seal ring of the water pump defect Excessive oil quantity in transmission REMEDY 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 sectio...

Page 77: ...CHNICAL SPECIFICATIONS 85 SX ENGINE 9 2 CARBURETOR 9 2 CHASSIS 9 3 STANDARD ADJUSTMENT SHOCK ABSORBER FORK 9 3 TOLERANCES AND FITTING CLEARANCES 9 4 TIGHTENING TORQUES ENGINE 9 4 TIGHTENING TORQUES CHASSIS 9 4 INDEX 9 1 TECHNICAL SPECIFICATIONS 9 ...

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Page 79: ... Primary drive straight cut spur gears 1 9 66 t Clutch multiple disc clutch in oil bath hydraulic operated Motorex Kupplungs Fluid 75 Transmission 6 speed claw actuated Gear ratio 1st gear 11 29 2nd gear 14 28 3rd gear 16 26 4th gear 19 26 5th gear 21 25 6th gear 20 21 Transmission oil 0 35 liter engine oil Motorex Topspeed 4T 15W50 Ignition system Moric Digital 2M1 Spark plug NGK BR 10 ECMVX Elec...

Page 80: ... mm Rear suspension WP PDS 4618 Progressive Damping System shock absorber Front brake Disc brake Ø 220 mm 4 piston Rear brake Disc brake Ø 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 46 t 14 49 t Chain 1 2 x 5 16 122 rolls Steering an...

Page 81: ...exagon nut front wheel spindle M 10x1 5 30 Nm Hexagon nut rear wheel spindle M 20x1 5 80 Nm Hexagon nut swingarm bolt M 14 M16x1 5 100 Nm Clamping bolts top triple clamp M 8 20 Nm Clamping bolts bottom triple clamp M 8 15 Nm Bolt handlebar clamp M 8 20 Nm Spoke nipple M 4 5 M5 5 Nm Other chassis bolts M 6 10 Nm M 8 25 Nm M 10 40 Nm TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES ENGINE Flange bolts ...

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Page 83: ...LUBRICATION AND MAINTENANCE SCHEDULE Repair manual KTM 85 SX Art No 3 206 008 E LUBRICATION AND MAINTENANCE SCHEDULE 85 SX 10 2 INDEX 10 1 10 ...

Page 84: ...ic systems emergency OFF switch or button Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake system bolts Check shock absorber and fork for leaks and function Clean dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings Ch...

Page 85: ...corrosion agent Check tightness of bolts nuts and hose clamps regularly For cross country use Once a year After every cleaning Before each start RECOMMENDED INSPECTION OF THE 85 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 c...

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Page 87: ...WIRING DIAGRAMS Repair manual KTM 85 SX Art No 3 206 008 E WIRING DIAGRAM 85 SX 11 2 INDEX 11 1 11 ...

Page 88: ...11 2 85 SX ignition coil 19 05 2003 U C E red black ye bl stop button red green green white black black blue white black orange red white pick up generator G 3 ...

Page 89: ...11 3 Repair manual KTM 85 SX Art No 3 206 008 E Cable colours bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple ...

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