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KTM 85SX Motorcycle User Manual

1. 3 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 We would like to point out that many operations cannot be performed by oneself In case of uncertainty please contact a KTM dealer 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 circuit switch faulty Loose ignition cable connectors Spark too weak Water in the carburetor and jets blocked Open fuel tap replenish fuel do not use choke The highly inflammable components in modern fuels volatilize if left standing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be drained from the float cham ber The engine will start up immediately if the float chamber is filled with fresh ignitable fuel Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out clean carburettor if no fuel leaks out check tank ventilation i e clean fuel tap Reduce electrode distance 0 60 mm Clean spark plug or
2. Fou L3 9 P dD Fou ng gt dD P ANI WARRAN ANL 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 Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting 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 The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifica tions must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified
3. 34 Cleaning the dust sleeves of the telescopic fork 17 TECHNICAL SPECIFICATIONS ENGINE 0000000 35 How to change the handlebar position 17 Changing the spring preloading of the shock absorber 17 CARBURETOR SETTING uu utut e Co SCR e ae 97 Basic suspension setup for the weight of the driver 18 HEAD WORD INDEX 38 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 1 A z Ts A i E T fis b Y IA i a OPERATION INSTRUMENTS Clutch lever The clutch lever 1 is located on the left side of the handlebar The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handle bars on the right and actu ates the front wheel brake The adjusting screw B is used to change the orig inal position of the hand brake lever see maintenance work on chassis and engine Short circuit button The short circuit button 1 turns off the engine When pressing this button the ignition circuit is short circuited Filler cap
4. Activate the cold starting aid choke 2 4 Leave throttle closed and kick down the kickstarter vigorously all the way AN WARNING eee AVOID INJURY WHEN STARTING THE ENGINE ALWAYS WEAR STRONG BIK ERS BOOTS YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY KICK BACK IF YOU DO NOT KICK HART ENOUGH DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS NESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION DO NOT RIDE YOUR MOTORCYCLE AT FULL LOAD AND DO NOT REV UP THE ENGINE WHEN COLD SINCE THE PISTON WARMS UP AND EXPANDS FASTER THAN THE WATER COOLED CYLINDER THIS MIGHT CAUSE ENGINE DAMAGE ALWAYS LET ENGINE IDLE UNTIL WARM OR DRIVE IT WARM AT LOW R P M SPEEDS NOTE The highly inflammable components in modern fuels volatilize if left stand ing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be drained from the float chamber The engine will start up immediately if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm 1 Open fuel tap 2 Put the gear in neutral 3 Leave throttle closed and kick down kickstarter vigorously all the way What to do when the engine is flooded 1 Close fuel tap 2 Start engine with full throttle If necessary unscrew spark plug and dry it 3 Once the engine is running open fuel tap again
5. After installing a different spring readjust the static sag to 30 35 mm According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari ous reasons If your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Overview of the telescopic fork springs If your child weights less than 50 kg or more than 60 kg have your KTM work shop mount suitable fork springs The illustration on the left shows the cor rect spring rate The standard spring is shown in bold print The type number of the telescopic fork is embossed on the inside of the fork leg According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring CICICBDCICS AND ENGIN 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 tensi
6. Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time 2 WARNING ee ALWAYS REMOVE THE PLUG IN 3 STAND BEFORE YOUR CHILD RIDES THE MOTOR CYCLE Shifting Riding You are now in first gear referred to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Turn down the throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and open the throttle If you turned on the choke make sure you turn it off again as soon as engine is warm 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 2 WARNING AFTER FALLING WITH THE MOTORCYCLE CHECK ALL ITS FUNCTIONS THOR OUGHLY BEFORE USING IT AGAIN A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STABILITY CAUTION DRIVING COLD ENGINE HIGH SPEED WILL REDUCE THE LIFE OF THE ENGINE WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL LOAD NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVERREV DAM AGING THE VALVES IN ADDITION THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY
7. THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE YOUR YOUNGSTER S DRIVING SPEED SHOULD ALWAYS ADJUSTED TO HIS HER DRIVING SKILLS AS WELL AS TO THE TERRAIN YOUR YOUNGSTER SHOULD NEVER BE ALLOWED TO RIDE THE MOTORCYCLE WITHOUT SUPERVISION REPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING SX MODELS ARE DESIGNED FOR ONE PERSON ONLY PASSENGERS ARE NOT ALLOWED THESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY STANDARDS ESTABLISHED BY THE LAW THEREFORE THEY ARE NOT PERMITTED ON PUBLIC ROADS ALWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCESSIVE NOISE 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 any oil leakage Too little gear oil will lead to premature wear and consequently destroy the transmission 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks 3 CHAIN A loose chain was fall off the chain whe
8. USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORRO SION AND COOLANT FOAMING Pressure induced by heating of the coolant in the system 15 controlled by a valve in the radiator cap 3 a water temperature rising up to 120 C 248 F is admissible without fear of problems Checking coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see illustr In the event of the coolant being drained always fill and bleed the system WARNING eee IF POSSIBLE ALWAYS CHECK THE LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE CAUTION THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQUID OR AFTER ADDING MORE THAN 0 25 L 0 06 US GALLONS COOLING LIQUID Refilling Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0 25 0 06 US gallons cooling liquid Make sure that the drain screw 4 is fastened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove the screw 5 on the right radiator Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the screw so that no more air can enter the right radiator up the left radiator until the coolant can be seen approx 10 mm 0 4 in above the rad
9. when engine is cold AND ENGIN Cooling system The water pump 1 in the engine keeps the cooling liquid 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 drained by removing the screw 2 on the water pump cover A re IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP 3 WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRES SURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS INCASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN IN CASE COOLANT IS INGESTED CONSULT A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDI ATELY AND CONSULT DOCTOR A mixture of 50 antifreeze liquid and 50 water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mix ture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE MOTOREX ANTI FREEZE
10. 02 22 clicks WARNING eee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 5 15MM Instructions for the first ride Make sure the work for the pre delivery inspection was per formed by your authorized KTM workshop The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle Before your youngster takes his or her first ride explain how each of the controls works and check if your youngster has understood what you explained We recommend to review the entire owner s manual with your youngster item by item pay ing particular attention to the specially marked warnings and pointing out the danger of injury Adjust the clutch lever hand lever and foot brake pedal so your child can operate them easily To prevent injury teach your youngster the basic riding skills on soft ground e g on a meadow or the garden Be sure that there 15 room enough to maneuver and that no other rid ers are close To ensure that your youngster gets the feel of the hand brake have your youngster operate the hand brake while you push the motorcycle Do not start the engine before your young Ster has learned to apply hand brake with appropriate pressure To familiarize your youngster with the operation of the hand
11. 6 Nm Loctite 243 12 Nm Loctite 243 12 Nm Other bolts 6 Nm 10 Nm VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 28 MEERESHOHE ALTIDUDE TEMPERATUR TEMPERATURE 20 C bis 7 C 85 SX 2006 6 C bis 5 C 2 F to 20 F 19 F to 41 F 6 C bis 15 C 42 F to 60 F 61 F to 78 F 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft 1501 5001 ft NEEDLE POS NEEDLE POS 1 5 1 75 45 42 N5HG N5HH 118 115 2 25 2 5 38 38 N5HH N5HH 1 115 115 1500 m 5000 ft t 751m 2501 ft 750 2500 ft 301 1001 ft NEEDLE POS NEEDLE POS 300 m 1000 ft t Meeresniveau Sea level NEEDLE POS MJ 16 C bis 24 C 25 C bis 38 C 79 F to 98 F LSO Luftregulierschraube offen LD Leerlaufd se POS Nadel Clip Position von oben HD Hauptd se NICHT F R STRASSENBETRIEB Kraftstoff Super Bleifrei ROZ 95 ASO IJ o pos MJ Air screw open from fully seated Idling jet Needle clip position from top Main jet NOT FOR HIGHWAY USE Fuel unleaded fuel with at least RON 95 USA Premium RON 91 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 27 153
12. Breather plug front fork 16 Carburetor adjustment 29 Carburetor setting ORC 37 Chain maintenance 39 29 5 1 3 9 ipe gee 20 Changing basic position of the brake pedal 23 Chaneine gear oil EE ERR 30 Changing the original position of the clutch lever 27 Changing the spring preloading of the shock absorber 17 CHASSIS o aap a al aie asa tow Sb ex abo a ne ROS 6 Checking and adjusting the steering head bearing 16 Checking chain tension 20 Checking coolant level 28 Checking front brake pads 22 Checking gear oil 30 Checking rear brake 23 Checking spoke tension 25 Checking the basic setup of the telescopic fork 19 Checking the brake fluid level refilling 22 Checking the oil level of the hydraulic clutch 27 Checking the rear brake fluid level 23 Checking the shock absorber and spring 18 CHOKE cute Sek dux eR dE TEX S ne ea I CENINGE a aia eek 33 Cleaning the air filter 26 Cleaning the dust sleeves of the telescopic fork 17 Oluten levelt cua wets owes dea ed 6 Compression damping of fork 8 Cooling System sux gu la ER SH RE ee es 28 Correct chain tensi
13. ON PARTS Check electric wires for damage and bends Check function of electric systems emergency OFF switch Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks BRAKES Check adjust smooth operation and free travel of handbrake foot brake lever Check the screws and guide bolts on the brake system for a tight fit Check shock absorber and fork for leaks and function Clean dust bellows Bleed fork legs Check swing arm bearings CHASSIS Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passage axle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and chain guides for wear fitment and tension WHEELS Lubricate chain Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 3 HOURS MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP IS NOT A SUBSTITUTE FOR CARE AND MAINTEN ANCE BY THE DRIVER 85 5 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN CARRIED OUT BY EXTRA ORDER At least once Every 2 years Clean and adjust carburetor Check the cylinder and piston for wear Check piston pin bearing Replace the crankshaft main bearings Replace the conrod
14. To open it turn filler cap counter clockwise To 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 is must be in the ON position to enable fuel to flow to the carburetor The tank will drain completely in this position Choke The choke button 3 is located on the left side of the carburetor Pulling the choke button 3 all the way out opens a bore in the carburetor through which the engine can take in additional fuel thus achieving the rich fuel air mixture needed for cold starting Pushing the choke button back in closes the bore in the carburetor Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown In the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled 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 The plug in stand 1 included in the scope of supply can be plugged into the left side of the bike at the end of the swinging fork Compression damping of fork Hydraulic compression damping determines the reac
15. be mounted on the fork and shock absorber for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring is suitable for your child s weight by checking the riding sag The static sag must be correctly adjusted before the riding sag can be determined IAK KIZA Determining the static sag of the shock absorber The static sag should be between 30 and 35 mm Larger deviations can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Aska helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B Cs YX3xocorx 160006000000 17 MS SAND 54 EXAMPLE Motorcycle jacked up dimension 600 mm Motorcycle on ground unloaded dimension B 565 mm icd teen 35 mm If the static sag is lower the spring preload of the shock absorber must be increased if the static sag Is reduced the spring preload must be higher See chapter Changing the sp
16. brake let him or her practice to operate the hand brake while you are pushing the motorcycle Do not start the engine before he or she is thoroughly familiar with the use of the hand brake Initially your youngster should ride back and forth between two persons who help the young rider to stop the motorcy cle However you should also teach your youngster how to stop the motorcycle himself herself To improve his her riding skills your youngster should prac tise riding the motorcycle standing on the footpegs or to rid ing at the slowest possible speed Additionally you can arrange a series of obstacles and have your youngster drive around them etc Pay attention to the running in procedure Running in Even very precisely machined sections of engine components have rougher surfaces than components which have been sli ing across one another for quite some time Therefore every engine needs to be broken in For this reason during its first 30 minutes the engine must not be revved up to its perform ance limits Apply low but changing loads for running in DO NOT DRIVE AT FULL LOAD FOR THE FIRST 30 MINUTES ARIIN 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 TO SET A GOOD EXAMPLE BE SURE TO WEAR PROTECTIVE GEAR YOURSELF WHENEVER RIDING A MOTORCYCLE ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM
17. in the maintenance schedule has been reached LT Za Ey In accordance with the international quality management ISO 9001 standard KTM uses REG NO 12 100 6061 quality assurance processes that lead to the highest possible product quality p p Fou gt p Fou B Fou p B CD gt Fou p The 85 SX mini motorcycles are off road motorcycles designed for one person only They are not allowed 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 Ib 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 To set a good example be sure to wear protective gear yourself whenever riding a motorcycle Before your youngster takes his or her first ride explain how each of the controls works and check if your youngster has understood what you explained We recommend to review the entire owner s manual with your youngster item by item paying particular attention to the specially marked warnings and pointing out the danger of injury Instruct your youngster about riding and falling techniques explain how the motorcycle will respond to shifting of the rider s weight etc Before starting the motorcycle for the first time check whether the basic fork and shock a
18. of cylin Check cylinder head replace O ring der head gasket leaks Excessive oil escapes from trans mission breather tube Excessive oil quantity trans mission Correct transmission oil level Water transmission oll Shaft seal ring of the water pump defect Replace shaft seal ring of the water pump 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 NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET OTHERWISE THE WATER MIGHT RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE MAILFUNCTIONS I E LEAD TO THE PREMATURE DESTRUCTION OF THESE PARTS You should use commercially available detergents to clean the motorcycle Heavily soiled parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and cloth Then take a short drive until the engine has reached its operating temperature and also operate the brakes The heat also causes the water at the inac cessible parts of the engine and the brakes
19. out a larger main Jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one AND ENGIN 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 Water in the float chamber leads to engine malfunction Make sure you do this while the engine is cold Close the fuel tap and place a cloth under the carburetor which is capable of absorbing the leaking fuel Unscrew the plug 1 and clean it with compressed air Then mount the plug together with the gasket and tighten to 4 Nm open fuel tap and check the float chamber for leaks AN WARNING Oe FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYS TEM NEAR OF OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF THE FUEL PROPERLY Checking gear oil level To check the gear oil warm up the engine to operating temperature with a low load and place the motorcycle on an even surface Remove the oil drain plug 2 and allow the gear oil to drain into a vessel Clean the seali
20. products or consequential damage resulting from the use of such products When special needs arise please contact a KTM dealer who will seek the assistance of the KTM importer if necessary PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends on the efforts made by the parents to ensure that the motorcycle is kept in good working order and only used on safe terrains Nevertheless driving the motorcycle like driving any other vehicle involves a potential risk Therefore please make sure that all fundamental precautions are taken Please also read the INFORMATION SAFE DRIVING FOR PARENTS on page 4 Riding an off highway motorcycle is a wonderful form of outdoor recreation and we certainly hope that you and your youngsters will enjoy it to the full However this enjoyable outdoor activity can cause envi ronmental problems or lead to conflicts with other people Responsible use of the motorcycle will prevent such problems and conflicts You can contribute to securing the future of motorcycling by making sure that you and your youngsters only use the motorcycle within the limits established by the applicable laws making environmental protection one of your top priorities and never violating other people s rights In this spirit we hope that you and your youngsters will always safely enjoy your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments 1 spare parts manual chassis amp engine
21. screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer AN WARNING eee SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOAD ING THE SPOKES MUST BE TENSIONED TO 5 NM AND ENGIN Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accumulated To 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 the filter support 3 from the filter box WARNING Oe DO NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY MOTOREX BIO DIRT REMOVER AND LIQUID BIO POWER FOR AIR FILTER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Mount the filter together with the filter support in the fil
22. when doubt please contact your importer Lubrication mixture lubrication Crankshaft bearing deep groove ball bearing cylinder roller bearing Connecting rod bearing needle bearing Oil gasoline ratio Piston pin bearing needle bearing Piston rings 1 compression ring Primary drive straight cut spur gears 19 66 t Clutch multiple disc clutch in oil bath hydraulic operated Motorex Kupplungs Fluid 75 Transmission 6 speed claw actuated 1 gear 11 29 2 gear 14 28 3 gear 16 26 4 gear 19 26 Gear ratio 5 gear 21 25 6 gear 20 21 Transmission oil 0 5 liter engine oil Motorex Topspeed 4T 15W50 Spark plug NGK BR 10 ECMVX Carburetor flat slide carburetor carburetor see table Coolant 1 liter mixture 50 antifreeze 50 distilled water at least 25 C 13 F Air filter wet foam type air filter insert BASIC CARBURETOR SETTING Carburetor Keihin PWK 28 Needle jet 2 6 Jet needle Throttle valve starting jet 62 Air adjustment screw open TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base Flywheel collar nut M 12X1 60 Nm Primary gear bolt Nut for inner clutch hub M 10X1 25 M 14X1 25 Loctite 243 80 Nm Loctite 243 60 Nm Crankcase and cover bolts M 6 8 Nm Spark plug Reed valve housing 14 1 25 14 1 5 20 Nm 100 Nm Kickstarter Shift lever Swingarm pivot M 6 M 6
23. 2006 855 ART NR 3 211 71EN IMPORTANT gt Please read this manual thoroughly before letting your youngster ride the motorcycle for the first time This manual contains important information and recommendations that will help you and your youngster to operate and handle the motorcycle properly In the interest of everybody involved we urge you to pay particular attention to instructions and information marked as follows ZN WARNING ee IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR CYCLE S TRAFFIC SAFETY Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained 15 without obligation KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applie
24. DICATES THAT THE BRAKE SYSTEM IS EITHER LEAKING OR THE BRAKE SHOES COMPLETELY WORN Refilling the rear brake fluid reservoir Remove the screws 3 and take off the cover 4 and diaphragm 5 The brake pistons must be pushed back to their basic position Fill DOT 5 1 brake fluid e g Motorex Brake Fluid DOT 5 1 up to 8 mm under the upper edge of the reservoir Remount the diaphragm cover and screws and actuate the foot brake lever until you feel the point of pressure again Wipe any overflowing or spilled brake fluid off with water WARNING ACTUATE THE FOOT BRAKE LEVER UNTIL YOU FEEL THE POINT OF PRESSURE AGAIN NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TOIT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking rear brake pads The brake pads can be Inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in WARNING OOOO AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFE
25. EX CROSS POWER 2T NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON WHEN USING TOO MUCH OIL THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG FUEL EXPANDS WHEN ITS TEMPERATURE RISES THEREFORE DO NOT FILL THE TANK TO THE TOP SEE FIG DO NOT USE PREMIXED TWO STROKE OILS OILS FOR OUT BOARD ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIX TURE DO NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN ONE WEEK THE LUBRICATION PROPERTIES OF SOME TWO STROKE OILS CAN DETERIORATE VERY RAPIDLY 85 5 2006 CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY im e Q p p a T o Zo 6 every 20 hours every 40 hours at least once Check gear box oil level Change gear box oil e Check spark plugs adjust distance between electrodes ENGINE Renew spark plugs Clean the spark plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check the carburetor connection boot and intake flange for cracks or leaks Check idle speed setting CARBURETOR Check that vent hoses are not damaged or bent Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box ADD
26. FECTS WOULD BE STRONGLY REDUCED AND ENGIN 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 Support Is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DIS MOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED IF THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PRE VENT THE THREAD FROM JAMMING The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm 60 ft Ib push the rear wheel forwards so that the chain tensioners lie on the tension screws WARNING eee IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FRO
27. GET OUT OF CONTROL IF THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL TRAVEL THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO ENSURE THAT IT IS SUPPLIED WITH SUFFI CIENT LUBRICANT WHICH IS MIXED IN THE FUEL IN THE EVENT THAT WHILE YOUR CHILD IS RIDING ON THE MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE YOUR CHILD SHOULD STOP IMMEDIATELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Turn off the gas and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed ART IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL Stopping Brake motorcycle and shift gears to idling To switch off the engine depress short circuit switch until the engine stops Close fuel tap A MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEA
28. H OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON IF YOU USE TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG IN THE CASE OF ALEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE NOTE Ifthe engine does not run properly despite a changed adjustment look for mechanical faults and check the ignition system Basic information on carburetor wear As a result of engine vibrations the throttle valve jet needle and needle jet are subjected to increased wear This wear may cause carburetor malfunction e g overly rich mixture Therefore these parts should be replaced after 1000 hours of using 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 To this end slightly increase the idling speed of the engine by means of the air control screw Turning it clockwise produces a higher idling speed and turn ing the screw counterclockwise produces a lower idling speed Create a round and stable engine speed using the air control screw basic position of the air control screw open by 1 5 turns Then adjust to the normal idling speed by means of the air control screw Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences
29. M OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle rides and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other Sharp objects that might have become embedded in them Tire pressure should be checked regularly on a cold tire Proper pressure 1 0 bar ensures optimum driving comfort and extends the life of your tires AN WARNING OOo DAMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNG STER WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW THE MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES PRESSURE BELOW THE NORMAL LEVEL WILL LEAD TO PREMATURE TIRE WEAR Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals For checking tap on each spoke with the blade of a
30. OTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHAN ICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put motorcycle on the stand so that the front wheel is off the ground Now try to move the fork forward and backward F
31. Oe THE SCREWS 5 MUST BE SECURED WITH LOCTITE 243 Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 6 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 6 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 7 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 7 tighten it to 8 Nm 6 ft Ib AND ENGIN Basic suspension setup for the weight of the driver To 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 shock absorber are set to accommodate a driver weighing between 50 and 60 kg wearing full protective clothing If your child s weight exceeds or falls short of this range you will need to adjust the spring components accord ingly Minor deviations in weight can be compensated by adjusting the spring pre load on the shock absorber Other springs must
32. T WHILE RUNNING THE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER STARTING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED CAUTION CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE THE PLUG IN STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY BY SITTING ON THE MOTORCYCLE YOUR CHILD WILL PUT ADDITIONAL WEIGHT ON THE PLUG IN STAND POSSIBLY CAUSING THE PLUG IN STAND OR SWINGING FORK TO BE DAMAGED OR THE MOTORCYCLE TO FALL DOWN Refueling fuel Oil high grade two stroke engine oil i e Motorex Cross Power 2T must be mixed with the fuel ROZ 95 at a mixing ratio of 1 40 AN WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIG ARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY CAUTION ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE ONLY USE KNOWN BRANDS OF HIGH GRADE 2 STROKE ENGINE OIL MOTOR
33. TATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT 15 AN EFFECTIVE PAINT REMOVER USEONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking front brake pads Inspect the brake pads from in front of the vehicle The linings must be at least 1 mm 0 04 in thick ZS AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD BE THINNER THAN 1 MM 0 04 IN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the front brake pads Remove the front wheel see front wheel chapter Press brake shoes apart with a suitable screwdriver to put the brake pistons in their basic position Remove the lock washer 4 from the screw as well as fixing screw 5 and take the brake shoes out of the brake caliper Clean brake caliper thoroughly with compressed air Mount the right brake shoe and fix with screw Mount the left brake shoe and tighten the screw to 4 Nm Mount the lock washer Align brake shoes mount front wheel see chapter Mounting the front wheel WARNING
34. TY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC AND ENGIN 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 and fix with bolt 2 Mount the locks 1 Tighten bolt 2 to 5 Nm 3 7 ft Ib A re IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY AFTER WORKING ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRES SURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on Its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 3 on the left side of the fork fists Loosen and remove the collar nut 4 loosen the clamping screews 5 on the right side of the fork fi
35. ads are pressed against the brake disc can be adjusted for any hand size CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 3 MM 0 1 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING AND ENGIN Checking the brake fluid level refilling The brake fluid reservoir is combined with the hand brake cylinder on the handlebar To check the brake fluid level press the brake pistons back into the basic position Move the hand brake cylinder in a horizontal position remove the screws 1 and the cover 2 with the diaphragm 3 The brake fluid level should be 5 mm below the upper edge of the reservoir see drawing otherwise add DOT 5 1 brake fluid e g Motorex Brake Fluid DOT 5 1 up to 5 mm below the upper edge of the reservoir Mount the diaphragm the cover and the screws and actuate the hand brake lever until you feel the point of pressure again Wipe off any overflowing or spilled brake fluid with water ACTUATE THE HAND BRAKE LEVER UNTIL YOU FEEL THE POINT OF PRESSURE AGAIN NEVER USE DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRI
36. ake fluid reservoir 23 Refilling Bleeding the cooling system 28 Refueling fuel 2 a cR ID SCC d RID UY ee ees 13 Replacing the front brake pads 22 FCU TIEHTIP HE os es s Ca RO e eS RC DEA 10 serial number locations 6 SITE NCVER 7 SHUE RIANNE Lue otis ead o qd Beg o qe o 12 SHOFECIFCULDE DURON ae eat es 7 Standard high speed setting 9 standard low speed setting 9 Stains qi ug doo c A C ob CS Ob ac oe C 12 starting when the engine is cold 12 starting when the engine is warm 12 EOD OIC ER Bac UU BN So 13 EP 33 Technical Specifications Chassis 34 Technical specifications engine 35 Tires air pressure 25 Trouble shooting suc m Sete ROS Brad we 3l Use after period of storage 33 What to do when the engine is flooded 12 What you should check before each start 11 HSITINS ENGLISH pri P Fr an INL RS KTM Group Partner
37. at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping Standard low speed setting Turn the adjusting screw 1 to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ WP Suspension 15187B02 15 clicks Standard high speed setting Turn the adjusting screw 2 to the limit in a clockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction WP Suspension 15187 02 2 turns AN WARNING eee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW 3 CONNECTION 24MM Rebound damping function of the shock absorber By using the adjusting screw 4 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber WP Suspension 15187
38. bearings Check the entire transmission the shift mechanism and bearings Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Replace the sealing cup for the foot brake cylinder Replace the glass fiber yarn filling in the silencer Treat electric contacts and switches with contact grease Change break fluid NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED 85 SX 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before each after every cleaning for cross country use Check gear box oil level Check brake fluid level Check brake pads for wear Lubricate and adjust cables and nipples Bleed fork legs regulary Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Remove clean and oil the throttle slide Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Check tightness of screws nuts and hose clamps regularly ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH ASTERISK REQUIRE SPECIALIST KNOWL EDGE FOR YOUR OWN SECURITY LET THESE TASKS BE CARRIED OUT BY A KTM DEALER WHERE YOUR M
39. bsorber settings are suitable for your child s weight see chapter on checking the basic chassis setting Before using the motorcycle you should always check all components for proper operation see mai nenance schedule Have your youngster perform these technical checks himself herself as well Whenever you go for a ride with your youngster keep in mind that the speed should be adjusted to your youngster and not the other way around Your youngster must understand that all instructions he or she receives from you or any other super vising adult must be followed Your child must be physically ready to ride a motorcycle This means that he or she must at least be able to ride a bicycle Being good at sports that require fast reactions is an additional advantage Your youngster should be strong enough to pick up the motorcycle after a fall Never demand too much of your youngster Give him or her time to get used to the motorcycle and to improve his her riding skills Do not even consider letting your youngster participate in a race before his her physical condition riding skills and motivation have sufficiently developed Explain to your youngster that he she should always adjust his her riding speed to the local condi tions as well as to his her own riding skills and that excessive speed can cause falls and severe inju ries Always keep in mind that youngsters tend to underestimate dangers or fail to recognize t
40. cylinder in a bubble free state Make sure that the oil does not overflow The bleeder syringe can be purchased from your KTM dealer Having completed the bleeding procedure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Clutchfluid 75 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 E G MOTOREX CLUTCHFLUID 75 TO FILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Adjusting the throttle cable There must always be a 3 5 0 1 0 2 in play in the throttle cable To check this move back the protective cover 8 on the throttle grip You must be able to lift the outer covering of the cable 3 5 mm from the adjusting screw 9 until resistance is felt To adjust loosen the counternut 10 and turn the adjusting screw accordingly Finally tighten the counternut and slide the protective cover back on To check the correctness of this setting start the engine turn the handlebar left and right in both cases as far as it will go This must not cause any changes in idling speed Otherwise you will have to increase the backlash of the throttle cable 10 mm
41. d to standard models 2004 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only Now own modern motorcycle that you and your youngster will certainly enjoy provided that you service and maintain it properly This manual contains important information on the operation and main tenance of your new KTM motorcycle It went to press describing your model s latest state of develop ment Nevertheless the descriptions may deviate slightly from the current design as our motorcycles are permanently improved The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chassis and engine must be performed by a KTM workshop If maintenance work should become neces sary during a competition it must be performed by a trained mechanic Please strictly observe the prescribed running in periods and inspection and maintenance intervals Compliance with these instructions will significantly prolong the life of your motorcycle Be sure to have the maintenance work carried out by a KTM workshop to avoid losing your right to claim under the warranty For the safety of your child only use spare parts and accessories approved by KTM KTM shall not assume any liability for other
42. eee IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY DO UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL HAVE TO BLEED THE BRAKE SYSTEM AFTER WORKING ON THE BRAKE SYSTEM ALWAYS OPERATE THE HAND BRAKE LEVER TO APPLY THE BRAKE PADS TO THE BRAKE DISK AND CREATE A POINT OF PRESSURE AND ENGIN 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 the push rod can move the piston in the brake cylinder to be recog nised from the resistance on the foot brake pedal AN WARNING Oe IF THIS CLEARANCE IS MISSING PRESSURE ACCUMULATES IN THE BRAKING SYS TEM AND THE BRAKE PADS BEGIN TO RUB THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES Checking the rear brake fluid level The reservoir for the rear disk brake is on the right side of the motorcycle on the rear brake cylinder The brake fluid level may not drop below the upper edge A of the inspection glass when the bike is in a horizontal position AN WARNING ee IF THE BRAKE FLUID LEVEL DROPS BELOW THE UPPER EDGE OF THE INSPEC TION GLASS THIS IN
43. els an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels 4 TIRES Check for damaged tires Tires showing cuts or dents must be replaced Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 BRAKES Check the correct functioning of the braking system Verify that there 15 Sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Always have the brake system checked by a KTM workshop to avoid brake failure Also check the state of the brake hose and the thickness of the brake linings Check free travel at the hand brake lever and foot brake lever WARNING Oe IF THE RESISTANCE IN THE HAND BRAKE LEVER FEELS SPONGY TOO MUCH PLAY THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T LET YOUR CHILD RIDE THE MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER 6 CABLES Check correct setting and easy running of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine 15 cold A Starting when the engine is cold 1 Open fuel tap 1 2 Put the gear in neutral
44. ess or damaged surface of reed valve housing damaged Wear Carburetor overflows if level adjust too high float needle seat ing Is dirty or enlarged Loose carburetor jets Incorrect heat range spark plug or low quality spark plug Loose corroded or non conduc tive ignition socket connector Replace reed paddles or reed valve housing Overhaul engine Clean carburetor if necessary replace float needle and adjust level Tighten jets Refer to technical data section Check and seal with silicon Engine spluters into the carburetor Lack of fuel Spark plug with incorrect heat value Ignition by incandescence Engine takes air out of control Clean fuel pipes examine tank aeration and clean Fit correct spark plug Check intake flange and carburettor firmly setted Engine overheating Insufficient liquid cooling system Radiator fins clogged Frothing in cooling system Pinched or kinked water hoses Incorrect ignition timing because of loose stator screws Incorrect compression ratio Top up coolant and bleed cooling system check cooling system for leaks Clean radiatar fins with water jet Renew coolant using branded anti freeze anti corrosive Motorex Anti Freeze Replace with correct routed hoses Readjust to correct ignition timing specifications secure screws with Loctite 243 Measure and adjust compression ratio Emission of white smoke steam Cylinder head or O ring
45. hem altogether The riding speed must be reduced in particular on unknown terrain Never let your youngster ride the motorcycle without supervision An adult should always be present motorcycle is designed for one rider only Your youngster is not allowed to transport a passenger When you go for a ride somebody at home should always know where you are going and when you will be back This makes it easier to send you help should problems occur Page Page IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE Checking the shock absorber and spring 18 DRIVING thes cin Se he BAe he ig hake tary eie UE c ia shes 4 Determining the static sag of the shock absorber 18 Determining the riding sag of the shock absorber 18 SERIAL NUMBER LOCATIONS 6 Overview of the shock absorber springs 19 Chassis TIUFTIDOE duis ae uat de c o Ec o EOD 6 Checking the basic setup of the telescopic fork 19 Engine number a abu so orb dee ARS 6 Overview of the telescopic fork springs 19 Checking chain tension 20 OPERATION INSTRUMENTS 6 Correct chain tension sume in gode dentato UE e ois 6 Chain maintenance aci ac Hand brake lever 6 General information about KTM disc brakes Short CLEC UTD UE OF qe uos de dudo e dE fai d o Adjusti
46. hydraulic clutch 2 RUNIE ATE nah acu UE tae a Pai CR COLOR at ECCLE NS 10 Bleeding of the hydraulic clutch 2 Adjusting the throttle cable 27 DRIVING INSTRUCTIONS 4 xr y RR RR 11 Coole Syste a u dt sae ob rac E Ra E 28 What you should check before each start 11 Checking coolant level 28 Starting when the engine is cold 12 Refilling Bleeding the cooling system 28 starting when the engine is warm 12 Carburetor adjustment 29 What to do when the engine is flooded 12 Draining the float chamber of the carburetor 30 o Velcro Pa cb NR 12 Checking gear oil 30 css aco de dc oe dolo sed e qo Meat 12 Changemg Sear Ol us seat eb qos deed ee ed aon 30 REO oium 3 dr CH Ed otra d e gov 1 9 Sic aep 19 TROUBLE SHOOTING tout etd ate pete dated n x 31 SIODDIDIB a le Sa Gk dob ee ah ab cde an cab eae 13 E EE Be a ae EN 33 PERIODIC MAINTENANCE SCHEDULE 14 STORAGE Te raae o ao CIAR 33 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 Use after period of storage 33 Checking and adjusting the steering head bearing 16 Breather plug front fork 16 TECHNICAL SPECIFICATIONS CHASSIS
47. iator fins Check the coolant level again after a short ride VAIN NAN UN AND ENGIN 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 Essential requirements are a clean air filter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle 15 sufficient and that changes to other parts of the carburetor will not greatly affect engine performance RULE OF THUMB high altitude or high temperatures choose leaner carburetor adjustment low altitude or low temperatures choose richer carburetor adjustment WARNING ONLY USE UNLEADED FUEL WITH AT LEAST RON 95 USA PREMIUM RON 91 MIXED WITH HIGH GRADE TWO STROKE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE AND THEIR USE WILL VOID YOUR WARRANTY ONLY USE HIGH GRADE 2 STROKE ENGINE OIL OF KNOWN BRANDS E G MOTOREX CROSS POWER 27 DO NOT USE PREMIXED TWO STROKE OILS OILS FOR OUTBOARD ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIXTURE NOT ENOUG
48. kg 68 kg Rear brake 70 100 19 Pirelli MT 32A 90 100 16 Pirelli MT 320 Rider s body weight max 75 kg Recommended age of rider 10 to 15 years Engine CR 85 STANDARD ADJUSTMENT FORK WP 4357 MXMA 05187B05 Compression adjuster 20 Rebound adjuster 20 Spring 3 N mm Air chamber length 110 mm Fork oil SAE 5 TIGHTENING TORQUES CHASSIS STANDARD ADJUSTMENT SHOCK ABSORBER WP 4618 PDS DCC WP 15187B02 15 LS Low SPEED Compression adjuster 2 HS HIGH SPEED Rebound adjuster Spring Spring preload Hexagon bolt brake caliper front Allan head screw brake pads rear Flat head bolt brake discs 8 Loctite 243 25 Nm M6 5 Nm M6 Loctite 243 10 Nm Hexagon nut front wheel spindle Hexagon nut rear wheel spindle M 10x 1 5 40 Nm M 20x1 5 80 Nm Hexagon nut swingarm bolt Clamping bolts top triple clamp Clamping bolts bottom triple clamp 14 M 16x1 5 5 Nm M8 20 Nm M8 15 Nm Bolt handlebar clamp Spoke nipple M8 20 Nm M 4 5 M 5 Other chassis bolts M6 M8 ENGINE 85 SX Design Liquid cooled single cylinder two stroke engine with reed valve intake Displacement 84 93 ccm Bore stroke 47 1 48 95 mm Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil 1 40 1 60 when using high grade two stroke oil e g Motorex 2T Crosspower
49. ng area mount the oil drain plug and gasket and tighten to 15 Nm Remove the oil filler screw 4 and add 0 5 liters of gear oil e g Motorex Topspeed 4T 15W50 Mount the oil filler screw and check the engine for leaks If the gear oil is still clean you can continue to use it up to your next service CAUTION LITTLE OIL OR A POOR OIL QUALITY WILL CAUSE THE TRANSMISSION TO WEAR PREMATURELY ONLY USE BRAND NAME OILS DUE TO A CHANGE IN THE FLUID CAPACITIES THE INSPECTION SCREW 3 CAN NO LONGER BE USED AN WARNING OO ENGINES AND ENGINE OIL ARE EXTREMELY HOT AT OPERATING TEMPERATURES BE CAREFUL NOT TO BURN YOURSELF Changing gear oil Before changing the gear oil warm up the engine and park the motorcycle on a horizontal surface Remove the oil drain plug 2 and drain the used oil into an appropriate container Clean the sealing surface Mount the oil drain plug together with its gasket and tighten to 15 Nm Remove the filler plug 4 and add 0 5 I gear oil e g Motorex Topspeed 4T 15W50 Mount the filler plug and check the engine for leaks CAUTION LITTLE OIL OR A POOR OIL QUALITY WILL CAUSE THE TRANSMISSION TO WEAR PREMATURELY ONLY USE BRAND NAME OILS DUE TO A CHANGE IN THE FLUID CAPACITIES THE INSPECTION SCREW 3 CAN NO LONGER BE USED AN WARNING Oe ENGINES AND ENGINE OIL ARE EXTREMELY HOT AT OPERATING TEMPERATURES BE CAREFUL NOT TO BURN YOURSELF TROUBLE SHOOTING gt
50. ng free travel of the hand brake lever PAIGE CID dore dote ce ate oe dh Sd soe doge Ran d Checking the brake fluid level refilling nit MNT EDAD Checking front brake pads CROKE unt oS uarie X ded ODE WEE POCO ERREUR S Replacing the front brake pads SIMTEIeVOE rs tara CER SECUS UC aba Via tO aes Changing basic position of the brake pedal idea 8 Checking the rear brake fluid level Foot DraKezDedal a a s ce RO OUR odo Ua c we OEC 8 Refilling the rear brake fluid reservoir PAIS zerr apes tet at Sha at 8 Checking rear brake pads Compression damping of fork 8 Dismounting and mounting the front wheel Rebound damping of fork 8 Dismounting and mounting the rear wheel Damping action during compression of shock absorber 9 Tires alt PrESSUIE os ig ae ea v Bas 25 Rebound damping function of the shock absorber 9 Checking spoke tension 25 Cleaning the air 26 GENERAL TIPS AND WARNINGS FOR STARTING THE Exhaust SYSTEM dece Neg doc E S da s uds 26 MOOR CNC IE erai er am a e d e inet dr en c 10 Changing the original position of the clutch lever 27 Instructions for the first ride 10 Checking the oil level of the
51. ntinue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid DOT 4 shown on the lid means minimum standard However you should replace it as soon as possible by DOT 5 1 AN WARNING re HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location B outside the contact face Check wear in several locations 2 WARNING OO BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 40 MM 0 016 IN CONSTITUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDI ATELY AS SOON AS THEY REACH THE WEAR LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A DEALER Adjusting free travel of the hand brake lever Free travel of the hand brake lever may be readjusted by using the adjust ment screw 2 In this way the position of the point of pressure i e the resist ance you feel on the hand brake lever when the brake p
52. on sadi eda cR 20 Damping action during compression of shock absorber 9 Determining the riding sag of the shock absorber 18 Determining the static sag of the shock absorber 18 Dismounting and mounting the front wheel 24 Dismounting and mounting the rear wheel 2b Draining the float chamber of the carburetor 30 Driving dstellc llols 3 arre oet ed e ORE Nau 11 Engine number aep X CRUCERO ENS 6 Page Exhaust system i 3 uc qua ous Sore E SE SOT oe be ar 26 gated eta le hee eds 7 Foot brake pedal 8 PUO Ta au wat Edu tuu e alee ws General information about disc brakes 21 General tips and warnings for starting the motorcycle 10 Hand brake 6 How to change the handlebar position 17 Important information for parents about safe driving 4 Instructions for the first ride 10 et Se hdc 2 Maintenance work on chassis engine 16 Operation instruments 6 Overview of the shock absorber springs 19 Overview of the telescopic fork springs 19 Periodic maintenance schedule 14 EU SLAIN ao tos Geman take Bee s 8 Rebound damping function of the shock absorber 9 Rebound damping 8 Refilling the rear br
53. oned The distance between the chain and the swing arm should be 5 6cm The lower part of the chain should be tightened Correct chain tension if necessary AN WARNING Oe IF THE CHAIN IS TOO TIGHT THE SECONDARY TRANSMISSION COMPONENTS CHAIN SPROCKETS BEARINGS OF THE TRANSMISSION AND OF THE REAR WHEEL WILL BE PUT UNDER ADDITIONAL STRAIN THAT CAN IN ADDITION TO PREMATURE WEAR ALSO CAUSE CHAIN BREAKAGE IF THE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN BOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm 60 ft Ib WARNING IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE NOTE The large adjusting range of the chain adjusters 32mm allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated b
54. or readjusting loosen the three clamp screws 1 of the top triple clamp and turn steering stem bolt 2 clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to release tension Retighten the three clamp screws to 20 Nm AN WARNING eee IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI ODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED O The steering head bearings should be regreased at least once a year i e Motorex Long Term 2000 cj 5 e A 00 Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 3 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF YOUR FORK IS LEAKING IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED AND ENGIN Cleaning the dust sleeves of the telescopic fork The dust protection bellows 1 are to remove dust and coarse dirt particle
55. renew Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate kickstarter a strong spark must be produced at the spark plug f no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstarter f a spark now occurs replace spark plug cap f no spark is produced control ignition system Disconnect black coloured cable from short circuit button at ignition coil and check ignition spark If the spark is O K repair defective part of cable or ignition switch Inspect cable connectors Examine ignition system Dismantle and clean carburetor Engine without idle running Idle adjusting screw out of adjustment Ignition system damaged Wear Readjust idle running or replace idle adjusting screw Examine ignition system Overhaul engine Engine has not enough power Charred glass fiber yarn in silencer Air filter obstructed Fuel supply partly interrupted or blocked Loss of compression through loose spark plug Exhaust system damaged Engine has not enough preignition Renew filling Clean or renew airfilter Blow through fuel pipe and clean carburetor Tighten spark plug Check exhaust system for damage Check and adjust ignition TROUBLE CAUSE REMEDY Engine has not enough power Engine revs not up and running in four stroke cycle High rpm misfiring Reed paddles tensionl
56. ring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle Your child should sit on the bike in a normal seating position feet on the footrests and bounce up and down a few times to allow the rear wheel suspension to become level With your child on the bike measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions and C 7 EXAMPLE Motorcycle jacked up dimension 600 mm T AVWA Motorcycle on ground loaded dimension C 510 mm R 90 riding sag should lie between 90 105 mm If the riding sag 15 less than 90 mm the spring 15 too hard the spring rate is too high If the riding sag is more than 105 mm the spring 15 too soft the spring rate is too low Shock absorber 40 215 30 215 40 45 50 99 60 65 70 75 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE Front fork 3 2 N mm 2 8 N mm SPRING RATE 40 45 50 59 60 65 70 75 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM AND ENGIN 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
57. s 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 it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with oil spray Motorex Joker 440 or engine oil Then push dust protection bellows into the outer tubes by hand AN WARNING eee NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper triple clamp 2 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 3 are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws 4 of the handlebar clamps and screws 5 of the handlebar support Position handlebar support and tighten screws 5 to 40 Nm Mount handlebar and handlebar clamps and tighten screws 4 to 20 Nm The gap between the handlebar support and handlebar clamps should be the same size in the front and in the rear 2 WARNING
58. st Hold the front wheel pull out the wheel spindle 6 Carefully remove the front wheel from the fork CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED To install the front wheel lift it into the fork position and mount the axle shaft Mount the collar nut 4 tighten the clamping screws 5 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 30 Nm 22 14ft Ib Loosen the clamp screws on the right fork leg Take the motorcycle down from Its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 1ONm 7ft Ibs WARNING ee IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE TIGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EF
59. t use airtight materials as possible humidity might not be able to escape and thereby cause corrosion IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE EXHAUST TO RUST Use after period of storage Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season CHASSIS 85 SX Frame Central chrome moly steel frame Fork telescopic fork WP Suspension 43 MXMA Wheel travel front rear 2 5 mm 300 mm Rear suspension WP PDS 4618 Progressive Damping System shock absorber Front brake Disc brake 0 220 mm 4 piston Disc brake 200 mm 4 piston Tires front 70 100 17 Pirelli MT 32A Tires rear 90 100 14 Pirelli MT 320 Air pressure 1 0 bar Fuel tank capacity 5 1 liter Final drive ratio 14 461 14 49t Steering angle 66 Seat height unloaded 865 mm Ground clearance 385 mm 415 mm Dead weight without fuel 66
60. ter box making sure to center them and fix them prop erly with the filter holding bracket Exhaust system The silencer is filled with glass fiber yarn for damping When in use the glass fiber yarn becomes loose or coked with oil carbon This can lead to a power loss and a reduction of the silencer damping The glass fiber yarn packing can be replaced in a few easy steps To replace remove the silencer from the vehicle and mark the position of the outer tube 4 to the inner tube 5 Remove screws 6 and the end cap 7 Pull of the outer tube and remove the old glass fiber yarn packing 8 from the inner tube Thoroughly clean all parts To assemble mount a new glass fiber yarn packing onto the inner tube see illustration and slide into the outer tube Mount end cap and fix with screws 6 Before tightening the screws turn the outer tube until they match the positions you marked Mount the silencer and check the exhaust system for tightness Note Glass fiber yarn packages are offered by your licensed KTM dealer AN WARNING THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN AND ENGIN 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 e
61. this range despite good idling speed and part throttle setting the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking a SS eS Eee EDEN EN jet needle n Part throttle range C SS Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main jet in the e WS RIN upper range If the engine runs on a four stroke cycle or with reduced power idling jet when it is accelerated with the throttle partly open the jet needle must be throttle valve lowered by one notch If the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised idling jet If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer gt Full throttle range D Operation with the throttle fully open flat out This range is influenced by the main jet and the jet needle If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings after a short dis tance of riding flat
62. tion when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap Turn the knob 2 clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 05187B05 20 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 3 REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding SIANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 05187B05 20 clicks 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 motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective
63. to evaporate Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Also treat the chain with a chain spray To prevent failures in the electric system you should treat the short circuit button with a contact spray If you want to put your motorcycle away for longer periods of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggressive contaminations Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel tap and wait until the engine dies off by itself In this way the carburetor jets are prevented from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kickstarter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate basin Correct tire pressure Lubricate bearing points of the control levers footrests etc as well as the chain The storage place should be dry and not be subjected to overly great temperature fluctuations Cover the motorcycle with an air permeable tarpaulin or blanket Do no
64. very hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER TAIN LIMITS ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM workshop CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Bleeding of the hydraulic clutch To bleed the cover of the master cylinder of the clutch needs to be removed For this purpose remove screws 2 and take off the cover 3 together with the rubber bellows 4 At the slave cylinder of the clutch remove the bleeder nipple 5 In its place mount the bleeder syringe 6 which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore 7 of the master
65. y 180 CAUTION ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED Chain maintenance For long chain life good maintenance 15 very important The chain should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray Motorex Chainlube 622 AN WARNING OOOO NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary AND ENGIN 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 20 Nm BRAKE FLUID RESERVOIRS The brake fluid reservoirs on front and rear wheel brakes have been designed in such way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake system with Motorex Brake Fluid DOT 5 1 one of the best brake fluids currently available We recommend that you co

KTM 85SX Motorcycle User Manual

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