2004–2009 KTM 85 SX / 105 SX Repair Manual Set (P/N 3.211.143 EN)

This KTM repair manual set covers the 2004–2009 85 SX and 105 SX, combining repair manual P/N 3.206.049-E with an owner's manual and WP suspension workshop manuals. Coverage includes the standard 17/14 and big-wheel 19/16 configurations.

The download is a single 254-page PDF containing four publications and a shared cover page.

• Engine repair: Engine removal and installation, crankcase separation, crankshaft and piston inspection, Nikasil-cylinder assessment, and cylinder exhaust-control adjustment.

• Clutch and transmission: Hydraulic clutch bleeding, outer clutch hub replacement, primary drive and kickstarter service, and mainshaft/countershaft assembly with revision notes.

• WP suspension: Fork cartridge, compression holder, and rebound assembly overhaul; shock piston-rod, DU-bush, reservoir, bleeding, and nitrogen-charging procedures.

• Fuel and cooling: Keihin PWK 28 carburetor adjustment, altitude/temperature jetting charts, reed-valve inspection, water-pump service, and cooling-system bleeding.

• Ignition diagnosis: Moric Digital 2M1 stator and ignition-coil resistance tests, peak-voltage checks, an electrical wiring diagram, and symptom/cause/remedy troubleshooting charts.

• Chassis maintenance: Periodic maintenance schedules, brake-fluid replacement, brake-pad and disc inspection, steering-head checks, wheel service, and suspension sag and spring-selection data.

The repair sections suit experienced mechanics with measuring equipment and the specified KTM/WP tools; the owner's manual distinguishes routine owner checks from work assigned to a KTM workshop.

Engine and Transmission Repair

The liquid-cooled two-stroke engine chapters cover crankcase bearings and seals, crankshaft inspection, piston-ring end gap, and cylinder/piston size matching. Separate procedures address the shift mechanism, reed valve housing and intake flange, centrifugal timer, and water pump.

Transmission revisions: Mainshaft notes identify the widened sixth-gear idler introduced at engine number B85 400300 and the later bushed arrangement from B85 500000. Countershaft instructions distinguish builds through 2005, the 2006 layout, and revisions from 2007.

These details help identify the correct gear, bearing, and spacer arrangement before selecting parts for a transmission repair.

Cylinder setup: Section views explain piston-to-cylinder dimension “X” and exhaust-control flap dimension “Z.” Adjustment and ignition-timing procedures identify different setting plates for the two engines: 470.29.006.000 for the 85 SX and 475.29.006.000 for the 105 SX.

The crankshaft section warns that improper clamping or hammering off the bearing inner ring can damage the crankshaft webs and connecting-rod bearing.

WP Fork and Shock Overhaul

The fork supplement covers 4357/4860 MXMA designs, including the WP 4357 MXMA telescopic fork listed in KTM's chassis specifications. Exploded views and illustrated procedures address screw caps, cartridges, compression and rebound shim assemblies, seals, DU-bushes, and oil-level adjustment.

The WP 4618 BAVP 85 SX shock manual covers piston-rod and reservoir rebuilding, the separation piston, and Dual Compression Control components. It also documents DU-bush calibration with T1205, bleeding, and nitrogen charging with T170S1.

Review the manual's safety precautions and torque requirements before major engine disassembly. The nitrogen-charged shock requires specialist handling and suspension service equipment.

Keihin Carburetion and Moric Ignition

Carburetor charts relate air-screw, idle-jet, main-jet, and needle settings to altitude and temperature. The 2009 chart specifically excludes highway use and sand tracks.

Ignition test instructions distinguish measurements with the CDI connected and disconnected, with photographs identifying the connections. The 85/105 SX/XC wiring diagram identifies the stop button, pickup, generator, ignition coil, and wire colors.

Troubleshooting charts cover starting faults, poor idle, power loss, misfiring, overheating, and water in the transmission oil.

Specification and Setup Data

Reference tables provide gear ratios, spacer and gasket dimensions, fitting clearances, wear limits, fluid capacities, and engine/chassis tightening torques. Illustrated special-tool references accompany the repair procedures, while spring-selection charts relate suspension setup to rider weight.

The specification and maintenance sections also include 2008–2009 85/105 SX/XC tables, with separate SX/XC suspension settings and identification of the XC O-ring chain.

PDF Contents and Navigation

The total includes the 2007 owner's manual, Art. No. 3.211.143 EN (38 pages); KTM repair manual (89 pages); WP fork manual (50 pages); WP shock manual (76 pages); and one shared cover page. All covers and section indexes are already included in these counts. Searchable text and embedded bookmarks cover all four publications; small wire-color labels in the wiring diagram require zooming for comfortable reading.