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KTM 85 SX manual

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  • Page 1

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 85 SX, XC 105 SX, XC OWNER’S MANUAL 2008 3211224 en *3211224en* 3211224en[...]

  • Page 2

    ENGLISH 1 INTRODUCTION » Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, construc[...]

  • Page 3

    ENGLISH 2 IMPORTANT INFORMATION » INTENDED PURPOSE KTM mini-sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. OWNER’S MANUAL Please read this manua[...]

  • Page 4

    ENGLISH 3 IMPORTANT INFORMATION » W ARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulat[...]

  • Page 5

    ENGLISH 4 IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING » The 85/105 SX/XC mini motorcycles are off-road motorcycles designed for one person only. They are not allo- wed on public roads. The vehicle dimensions and components are designed for children from 10 to 15 years of age with a maximum weight of 75 kg (33,98 lb). – Have your youngst[...]

  • Page 6

    ENGLISH 5 TABLE OF CONTENTS » Page IMPOR T ANT INFORMA TION FOR P ARENTS ABOUT SAFE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .6 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Engine number . . . . . . . . . . . . . . . . . [...]

  • Page 7

    ENGLISH 6 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor . Enter this number in the field on page no 1. Clutch lever The clutch lever [1] is l[...]

  • Page 8

    ENGLISH 7 OPERATION INSTRUMENTS » Filler cap T o open it: turn filler cap counter-clockwise. T o close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor . ON When the motorcycle is running the grip[...]

  • Page 9

    ENGLISH 8 OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work). Plugin- Stand (SX) The plug-in stand [1] incl[...]

  • Page 10

    ENGLISH 9 OPERATION INSTRUMENTS » Damping action during compression of shock absorber The shock absorber on the models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcyc[...]

  • Page 11

    ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye protection, chest, back, arm and leg protectors, gloves and boots. T o set a good example, be sure to wear protective gear yourself whenever riding a motorcycle! – Only use ac[...]

  • Page 12

    ENGLISH 11 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECKING THE ENGINE Check the engine for [...]

  • Page 13

    ENGLISH 12 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap [1] . 2 Put the gear in neutral 3 Activate the cold-starting aid (choke) [2] . 4 Leave throttle closed and kick down the kickstarter vigorously all the way . – T o avoid injury when starting the engine, always wear strong bikers boots!Y ou may slip off the kicksta[...]

  • Page 14

    ENGLISH 13 DRIVING INSTRUCTIONS » 40 mm When shifting down, use the brakes if necessary and turn down at the same time. Pull clutch lever and shift down to the next lower gear . Let the clutch lever go slowly and open throttle or shift down again. – After falling with the motorcycle, check all its functions thoroughly before using it again. – [...]

  • Page 15

    ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » 85/105 SX/XC 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY before each race 1st service after 10 hours every 20 hours every 40 hours at least once a year ENGINE Check gear box oil level z Change gear box oil z z z z Check spark plugs, adjust distance between electrodes z z Renew sp[...]

  • Page 16

    ENGLISH 15 PERIODIC MAINTENANCE SCHEDULE » 85/105 SX/XC 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Every 20 hours Every 40 hours At least once a year Every 2 years Clean and adjust carburetor z Check the reed-type intake valve for wear z z Check the wear on the clutch disks and length of[...]

  • Page 17

    ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking and adjusting the steering head bearing * Check steering head bearing for play periodically . T o check, put motorcycle on the stand so that the front wheel is off the ground. Now try to move the fork forward and backward. For readjusting, loosen the three clamp screws [1] of the top tri[...]

  • Page 18

    ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind i[...]

  • Page 19

    ENGLISH 18 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the fork, shock absorber , swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your child's weight. At delivery , the fork and sho[...]

  • Page 20

    ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » Overview of the shock absorber springs The spring rate is written on the outside of the spring (e.g. 35-215). The type number of the shock absorber is embossed on the top. The illustration on the left shows which spring should be installed. The stan- dard spring is shown in bold print. After inst[...]

  • Page 21

    ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » A Checking chain tension Support the motorcycle on the center stand or side stand, respectively . Switch transmission to neutral. Push the chain upwards from the end of the chain sliding component until the upper part of the chain is tensioned. The distance between the chain and the swing arm sho[...]

  • Page 22

    ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: If the front brake caliper is removed, the screws must be secured with Loctite 243 when mounted and tightened to 25 Nm. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on front and rear wheel brakes have been designed in such a way that[...]

  • Page 23

    ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 2 3 5 mm min. 1 mm 4 5 1 Checking the brake fluid level/ refilling * The brake fluid reservoir is combined with the hand brake cylinder on the handlebar . T o check the brake fluid level, press the brake pistons back into the basic position. Move the hand brake cylinder in a horizontal position[...]

  • Page 24

    ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1] . Using the push rod [2] , the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play before[...]

  • Page 25

    ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » Remove the safety device [1] , knock out the guide pin [2] from the brake caliper with a drift towards the chain wheel and remove the brake pads. Carefully clean the brake caliper with compressed air and check the sleeves of the guide pins for damage. Press both brake shoes into the brake caliper[...]

  • Page 26

    ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Loosen the collar nut [1] , remove chain tensioner [2] , hold the rear wheel and pull out the wheel spindle [3] until the rear wheel is free but the brake caliper suppo[...]

  • Page 27

    ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accumulated. T o clean, lift the filter box cover (see illustration) and pull off towards the front. Detach the filter retainer [1] at the bottom, tilt to the side and remove the air filter [2] and th[...]

  • Page 28

    ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size. T urning the adjusting screw counterclockwise reduces the distance b[...]

  • Page 29

    ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cooling system The water pump [1] in the engine keeps the cooling liquid in circulation. The cooling liquid is cooled by the air stream. Therefore, the cooling effect is reduced when the traveling speed is reduced. Dirty radiators additionally reduce the cooling effect. The cooling liquid can be [...]

  • Page 30

    ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw [1] and the air control screw [2] . Only make adjust- ments when the engine is hot. T o this end, slightly increase the idling speed of the engine by means of the air control scr[...]

  • Page 31

    ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber leads to engine malfunction. Make sure you do this while the engine[...]

  • Page 32

    ENGLISH 31 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine fails to start Operating error The motorcycle was not driven for a longer period of time, leaving old fuel in the float chamber Fuel supply interrupted Electrode distance too great Plug fouled by oil, wet or bridged Ignition wire or spark plug con- nector damaged Kill button wire or short-c[...]

  • Page 33

    ENGLISH 32 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine has not enough power Reed paddles tensionless or damaged, surface of reed valve housing damaged W ear Replace reed paddles or reed valve housing Overhaul engine Engine revs not up and running in four stroke cycle Carburetor overflows if level adjust too high, float needle seat- ing is dirty[...]

  • Page 34

    ENGLISH 33 CLEANING » STORAGE » 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. Th e hard dirt can be removed before with the help of a soft water jet. Never clean your motorcycle[...]

  • Page 35

    ENGLISH 34 TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 85 SX/XC (17”/14”) 85 SX 105 SX/XC (19”/16”) Frame Central chrome-moly-steel frame Fork telescopic fork WP Suspension 4357 MXMA Wheel travel front/rear 275 mm / 300 mm (10.82/11.81 in) Rear suspension WP PDS 4618 (Progressive Damping System) shock absorber Front brake Disc brake Ø [...]

  • Page 36

    ENGLISH 35 TECHNICAL SPECIFICATIONS - CHASSIS » TIGHTENING TORQUES - CHASSIS Hexagon bolt - brake caliper front M 8 Loctite 243 + 25 Nm Allan head screw - brake pads rear M6 5 Nm Flat head bolt - brake discs M6 14 Nm Hexagon nut - front wheel spindle M10x1.5 40 Nm Hexagon nut - rear wheel spindle M20x1.5 80 Nm Hexagon nut - swingarm bolt M14/M 16x[...]

  • Page 37

    ENGLISH 36 TECHNICAL SPECIFICATIONS - ENGINE » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 6 10 Nm Nuts-cylinder base M 8 30 Nm Flywheel collar nut M 12X1 60 Nm Primary gear bolt M 10X1,25 Loctite 243 + 80 Nm Nut for inner clutch hub M 14X1,25 Loctite 243 + 60 Nm Crankcase and cover bolts M 6 8 Nm Spark plug M 14X1,25 20 Nm Reed va[...]

  • Page 38

    ENGLISH 37 CARBURETOR SETTING » VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 28 85/105 SX/XC 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F to 41°F 6°C bis 15°C 42°F to 60°F 16°C bis 24°C 61 °F to 78°F 25°C bis 38°C 79°F to 98°F 3000 m 10000 ft 2301 m 7501 ft LSO ASO LD IJ [...]

  • Page 39

    HEAD WORD INDEX » ENGLISH 38 Page Adjusting free travel of the hand brake lever . . . . . . .21 Adjusting the throttle cable . . . . . . . . . . . . . . . . . . .27 Basic suspension setup for the weight of the driver . . .18 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .27 Braking . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    ENGLISH 39[...]

  • Page 41

    ENGLISH 40[...]

  • Page 42

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 85 SX, XC 105 SX, XC OWNER’S MANUAL 2008 3211224 en *3211224en* 3211224en[...]