KTM 85 SX 2004 Repair Manual
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KTM 85 SX 2004 Repair Manual

1-cylinder, 2-stroke engine
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REPAIRMANUAL2004
85 SX
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN

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Summary of Contents for KTM 85 SX 2004

  • Page 1 REPAIRMANUAL2004 85 SX REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
  • Page 3 KTM Group Partner...
  • Page 5 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 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...
  • Page 7 M P O RTA N T N F O R M AT I O N KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index 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.
  • Page 9 X P L A N AT I O N P D AT I N G This repair manual contains the following supplements: 3.206.008-E Repair Manual 85 SX Basicversion Modelyear 2004 06/2003 Edition 06/2003...
  • Page 11 „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. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow.
  • Page 13 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 –...
  • Page 15 GENERAL INFORMATION INDEX CARBURETOR ADJUSTMENT ........2-2 BLEEDING OF THE HYDRAULIC CLUTCH .

  • Page 17: Carburetor Adjustment

    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.

  • Page 18: Bleeding Of The Hydraulic Clutch

    – H AVING 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 EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS –...

  • Page 19: Special Tools

    SPECIAL TOOLS – ENGINE 85 SX HOLZGABEL SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE FIG. DESCRIPTION PART NUMBER 560.12.001.000 Universal engine work stand 470.29.027.000 Clutch rivetting tool 6 899 785 Loctite 243 blu 6 cm 510.12.011.000 Circlip plier 503.29.050.000 Vent syringe for hydraulic clutch 546.29.009.044 Magneto extractor M 27x1 510.12.016.000...

  • Page 20: Cleaning

    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 EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...
  • Page 21 DISMOUNTING AND MOUNTING THE ENGINE INDEX DISMOUNTING THE ENGINE ........3-2 MOUNTING THE ENGINE .
  • Page 23 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.
  • Page 24 – Remove the bolt of the rear exhaust bracket – 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. –...
  • Page 25 – 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 –...
  • Page 26 Installing the engine – Lift the engine into the frame and correctly position it. – Slightly grease the two engine fixing bolts and mount but do not tighten yet. – Slightly grease the swing arm pivot, mount the hexagon nut tighten to 100 Nm.
  • Page 27 – 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 – Hook the spring – Correctly position the tank and mount the bolt with the tank roller, tighten the bolt to 10 Nm.

  • Page 28: Bleeding The Cooling System

    Refilling/Bleeding 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.

  • Page 29: Table Of Contents

    DISASSEMBLING THE ENGINE INDEX CLAMP THE ENGINE INTO THE MOUNTING RACK, REMOVING OF KICKSTARTER ........4-2 DRAINING GEAR OIL .

  • Page 31: Draining Gear Oil

    – 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 engine is dismounted, otherwise the gear oil may run out through the main shaft when the clutch slave cylinder is removed.

  • Page 32: Dismounting Of Clutch Cover

    – 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. –...

  • Page 33: Dismounting The Clutch

    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.

  • Page 34: Dismounting The Kickstarter Unit

    – 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. –...

  • Page 35: Dismounting The Ignition

    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 the flywheel extractor 546.29.009.044 and remove the flywheel.

  • Page 36: Dismounting Of Intake Flange And Reed Valve Housing

    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. –...
  • Page 37 – 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 –...
  • Page 39 SERVICING ON INDIVIDUAL COMPONENTS INDEX WORKING ON THE RIGHT-HAND HOUSING HALF ....5-2 WORKING ON THE LEFT-HAND HOUSING HALF ....5-3 CRANKSHAFT .
  • Page 41 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 housinq half on a plane piece of wood when the housing has a temperature of 150°...
  • Page 42 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 housinq half on a plane piece of wood when the housing has a temperature of 150°...
  • Page 43 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.
  • Page 44 Checking cylinder for wear – To check the wear on the cylinder, measure the cylinder 20 mm 20mm 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.
  • Page 45 LOCTITE 243 LOCTITE 243 Cylinder exhaust control system Dismantle and clean all exhaust control components, check for signs of wear and damage. Bearing sleeves – Check bearing sleeves of the control flap for play and easy operation. Control flap – 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 flap for wear and replace if necessary.
  • Page 46 LOCTITE 243 Dismounting 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 out of the housing. –...
  • Page 47 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 243. ECURE ALL BOLTS OF THE REED VALVE HOUSING WITH OCTITE Intake flange Check for firm mounting and for signs of damage. LOCTITE 243 LOCTITE 243...
  • Page 48 Clutch Thrust bearing check for wear Push rod Check for wear (length 113 mm). Clutch springs All 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).
  • Page 49 5-10 Replace outer clutch hub – Drill open the clutch rivets in area of retaining bracket 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 –...
  • Page 50 5-11 LOCTITE 243 LOCTITE 243 LOCTITE 243 Disassembling the shifting shaft – Clamp the shifting shaft into the vise (use protective jaws). – Remove the return spring and twist the spring holder off the shifting shaft – Take the shift quadrant off the shifting shaft together with the slide plate...
  • Page 51 5-12 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 –...
  • Page 52 5-13 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 –...
  • Page 53 5-14 LOCTITE 243 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 Check the bearing for clearance and seizing marks. Check the toothing for wear.
  • Page 55 ASSEMBLING THE ENGINE INDEX CRANKSHAFT ..........6-2 TRANSMISSION .
  • Page 57 – Secure the right-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 HEN PUSHING IN CRANKSHAFT MAKE SURE CONROD IS FACING CYLINDER NOTE: To make it easier to mount the crankshaft, heat the crankshaft bearing with a hot air blower.
  • Page 58 – Fix the 4 pressure springs with ample amounts of grease in the gearshift rails. – Oil gearshift rails and insert them into the gearshift forks (short 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.
  • Page 59 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. –...
  • Page 60 – 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.
  • Page 61 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. –...
  • Page 62 – 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 –...
  • Page 63 Adjusting dimension „X“ Dimension „X“ is the dimension from upper edge of piston to upper edge of cylinder with cylinder under low tension and piston in TDC position. The dimension „X“ should be adjusted extremely carefully by inserting cylinder base gaskets of suitable thicknesses. CAUTION „X“...
  • Page 64 Adjusting control flap (dimension “Z“) control NOTE: Dimension “Z“ is the distance from the lower edge of the control flap 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. Dimension „Z“...
  • Page 65 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.
  • Page 66 6-11 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.
  • Page 67 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. –...
  • Page 69 ELECTRICAL INDEX RESISTOR VALUES OF THE IGNITION SYSTEM - STATOR ....7-2 IGNITION COIL ..........7-2 MEASURING STATIC IGNITION VALUES WITH PEAK VOLTAGE ADAPTER .
  • Page 71 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: 310 Ω +/- 60 Ω CDI voltage supply: between the green/blue and black cable Multimeter display: 55 Ω...
  • Page 72 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 –...
  • Page 73 TROUBLE SHOOTING INDEX TROUBLE SHOOTING 85 SX ........8-2...

  • Page 75: Trouble Shooting

    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...
  • Page 76 TROUBLE CAUSE REMEDY Engine has not enough Reed paddles tensionless Replace reed paddles or reed valve housing power damaged, surface of reed valve housing damaged Wear Overhaul engine Engine revs not high and Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust running with four stroke too high, float needle seating is level...
  • Page 77 TECHNICAL SPECIFICATIONS INDEX TECHNICAL SPECIFICATIONS 85 SX ENGINE ........... . .9-2 CARBURETOR .
  • Page 79 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.
  • Page 80 TECHNICAL SPECIFICATIONS – CHASSIS 85 SX 2004 Frame Central chrome-moly-steel frame Fork telescopic fork White Power 43 MXMA Wheel travel front/rear 275 mm / 300 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...
  • Page 81 TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0.045 – 0.07 mm Piston ring end gap max. 0.3 mm Connecting rod bearing - radial clearance max 0.03 mm Clutch springs - length new = 34 mm, minimum length = 33 mm 47 mm ±...
  • Page 83 10-1 LUBRICATION AND MAINTENANCE SCHEDULE INDEX LUBRICATION AND MAINTENANCE SCHEDULE 85 SX ....10-2...

  • Page 84: Periodic Maintenance Schedule

    10-2 PERIODIC MAINTENANCE SCHEDULE 85 SX 1st service after after after 10 hours 20 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 1000 kilometers 2000 kilometers once a year Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs...
  • Page 85 10-3 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER 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...

  • Page 87: Wiring Diagrams

    11-1 WIRING DIAGRAMS INDEX WIRING DIAGRAM 85 SX ........11-2...
  • Page 88 11-2...
  • Page 89 11-3 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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