Tolerances And Fitting Clearances; Gasket Thicknesses; Tightening Torques - Engine; Tightening Torques - Chassis - KTM 85 SX 2004 Repair Manual

TOLERANCES AND FITTING CLEARANCES

Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Clutch springs - length
Crankshaft web

GASKET THICKNESSES

Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket
Outer clutch cover
Water pump cover

TIGHTENING TORQUES - ENGINE

Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Primary pinion bolt
Nut for inner clutch hub
Crankcase and cover bolts
Spark plug
Reed valve housing
Kickstarter
Shift lever
Swingarm pivot
Other bolts

TIGHTENING TORQUES - CHASSIS

Hexagon bolt - brake caliper
Flat head bolt - brake discs
Hexagon nut - front wheel spindle
Hexagon nut - rear wheel spindle
Hexagon nut - swingarm bolt
Clamping bolts - top triple clamp
Clamping bolts - bottom triple clamp
Bolt - handlebar clamp
Spoke nipple
Other chassis bolts
0.045 – 0.07 mm
max. 0.3 mm
max 0.03 mm
new = 34 mm, minimum length = 33 mm
47 mm ± 0,05 mm
0.5 mm
0.5 mm
as required
0.2/0.3/ 0.5 mm
O-rings
O-ring
O-ring
M 6
M 8
M 12x1
M 10x1.5 Loctite 243 80 Nm
M 14x1.5 Loctite 243 60 Nm
M 6
M 14x1.25
M 6
M 6 Loctite 243 12 Nm
M 6 Loctite 243 12 Nm
M 14x1.5
M 5
M 6
M 8 Loctite 243 + 25 Nm
M6 Loctite 243 + 10 Nm
M 10x1.5
M 20x1.5
M 14/M16x1.5
M 8
M 8
M 8
M 4,5/M5
M 6
M 8
M 10
9-4
10 Nm
30 Nm
60 Nm
8 Nm
20 Nm
6 nm
100 Nm
6 Nm
10 Nm
30 Nm
80 Nm
100 Nm
20 Nm
15 Nm
20 Nm
5 Nm
10 Nm
25 Nm
40 Nm