This comprehensive service manual for the KTM 85sx and KTM 105sx two-stroke motorcycles, covering model years 2004 to 2009, provides a complete guide for both amateur and professional mechanics. It includes detailed instructions and illustrations for complete tear-down and rebuild procedures, covering all aspects of the motorcycle, from the engine to the suspension.

The manual features clear diagrams and step-by-step instructions, along with essential information like torque specifications, maintenance schedules, and troubleshooting tips. You'll find guidance on a wide range of topics, including:

* **Engine:** Detailed procedures for rebuilding the engine, including the crankshaft, connecting rod, piston, cylinder, and head. You'll also find information on the ignition system, carburetion, and exhaust.
* **Transmission:** Instructions for disassembling and reassembling the gearbox, including gear changes, clutch adjustments, and chain maintenance.
* **Suspension:** Comprehensive coverage of the front forks and rear shock, including procedures for rebuilding and adjusting suspension components.
* **Electrical System:** Detailed diagrams and information for troubleshooting and repairing the electrical system, including the starter, battery, lighting, and charging system.
* **Bodywork:** Instructions for removing, repairing, and reassembling the body panels, fairings, and other components.
* **Maintenance:** Complete schedules and procedures for routine maintenance, including oil changes, air filter cleaning, and lubrication.

This manual is your one-stop resource for all your KTM 85sx and KTM 105sx repair and maintenance needs. It is designed to be easy to use, with searchable content and clickable chapters, allowing you to quickly find the information you need.

The KTM 85 SX and 105 SX are high-performance, off-road motocross motorcycles designed for young and aspiring racers. These machines are renowned for their lightweight, powerful, and agile design, allowing riders to tackle challenging terrain with confidence and speed. The 85 SX features a liquid-cooled, 85cc, two-stroke engine, while the 105 SX boasts a slightly larger, 105cc, two-stroke engine. Both models are equipped with a six-speed transmission, providing riders with a wide range of gear ratios to suit various track conditions. Additionally, these bikes incorporate high-quality suspension components from WP Suspension, known for their exceptional handling and performance. Features such as a lightweight aluminum frame, a hydraulic clutch, and a powerful braking system contribute to the overall performance and durability of these motocross machines.

The KTM 85 SX and 105 SX have been widely praised for their handling characteristics, power delivery, and overall racing prowess. They are popular choices for young riders competing in the 85cc and 105cc classes of amateur motocross events, allowing them to develop their skills and experience the thrill of racing on a high-performing machine. However, it's important to note that these motorcycles are designed for experienced riders and may not be suitable for beginners or casual riders. Their high performance and aggressive nature require a certain level of skill and knowledge to handle safely. Proper training and safety precautions should always be prioritized when riding these motorcycles.