KTM 105 XC 2008 Owner's Manual
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KTM 105 XC 2008 Owner's Manual

Ktm owner's manual motorcycle85 sx, xc 105 sx, xc
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OWNER'S MANUAL
2008
85 SX, XC
105 SX, XC
3211224en

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Summary of Contents for KTM 105 XC 2008

  • Page 1 OWNER’S MANUAL 2008 85 SX, XC 105 SX, XC 3211224en...
  • Page 2 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 applied to standard models.

  • Page 3: Important Information

    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.
  • Page 4 SPARE PARTS, ACCESSORIES For the safety of your child, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

  • Page 5: Driving

    – 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.

  • Page 6: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......10 Instructions for the first ride ....10 Running in .

  • Page 7: Serial Number Locations

    SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » 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.

  • Page 8: Short Circuit Button

    In this position the fuel tap is closed. No fuel can flow to the carburetor. 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.

  • Page 9: Kickstarter

    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).

  • Page 10: Damping Action During Compression Of Shock Absorber

    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 at fast compression...

  • Page 11: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 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.

  • Page 12: Driving Instructions

    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.

  • Page 13: Starting When The Engine Is Cold

    Always pro- vide adequate ventilation while the engine is running. 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.

  • Page 14: Refueling, Fuel

    Also change down to lower gears depending on your speed. – 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.

  • Page 15: Periodic Maintenance Schedule

    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 maintenance by the driver! »...
  • Page 16 » PERIODIC MAINTENANCE SCHEDULE 85/105 SX/XC 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs...

  • Page 17: Maintenance Work On Chassis And Engine

    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.

  • Page 18: Cleaning The Dust Sleeves Of The Telescopic Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE 3,5 mm 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.

  • Page 19: Basic Suspension Setup For The Weight Of The Driver

    EXAMPLE: Motorcycle jacked up (dimension A) ..... .600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag .

  • Page 20: Overview Of The Shock Absorber Springs

    Overview of the telescopic fork springs If your child weights less than 45 kg or more than 55 kg, have your KTM work- shop mount suitable fork springs. The illustration on the left shows the cor- rect spring rate.

  • Page 21: Checking Chain Tension

    – 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 behavior of your motorcycle.

  • Page 22: General Information About Ktm Disc Brakes

    DOT 4 brake fluid. Do not, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motor- cycle gaskets and brake hoses are not designed for DOT 5 brake fluid.

  • Page 23: Checking The Brake Fluid Level/ Refilling

    MAINTENANCE WORK ON CHASSIS AND ENGINE min. 1 mm 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.

  • Page 24: Changing Basic Position Of The Brake Pedal

    3-5mm 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.

  • Page 25: Dismounting And Mounting The Front Wheel

    – 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 behavior of your motorcycle.

  • Page 26: Dismounting And Mounting The Rear Wheel

    – 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 behavior of your motorcycle.

  • Page 27: Cleaning The Air Filter

    Mount the silencer and check the exhaust system for tightness. Note: Glass fiber yarn packages are offered by your licensed KTM dealer. 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.

  • Page 28: Changing The Original Position Of The Clutch Lever

    SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore [7] of the master 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...

  • Page 29: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE 10 mm when engine is cold 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.

  • Page 30: Carburetor Adjustment

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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 - 1:60 .

  • Page 31: Draining The Float Chamber Of The Carburetor

    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 sealing area, mount the oil drain plug and gasket and tighten to 15 Nm.

  • Page 32: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 33 TROUBLE SHOOTING TROUBLE Engine has not enough power Engine revs not up and running in four stroke cycle High rpm misfiring Engine spluters into the carburetor Lack of fuel Engine overheating Emission of white smoke (steam) Cylinder head or O-ring of cylin- Excessive oil escapes from trans- mission breather tube Water in transmission oil...

  • Page 34: Cleaning

    – 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 a cloth. Then take a short drive until the engine has reached its operating temperature, and also operate the brakes.

  • Page 35: Technical Specifications - Chassis

    LOW SPEED Compression adjuster HIGH SPEED Rebound adjuster Spring Spring preload » 85 SX 105 SX/XC (19”/16”) 70/100-19“ Pirelli NHS 42M 90/100-16“ Pirelli NHS 51 14 : 49 t 1/2 x 5/16" O-Ring 122 rolls (XC) 900 mm 415 mm...
  • Page 36 TECHNICAL SPECIFICATIONS - CHASSIS TIGHTENING TORQUES - CHASSIS Hexagon bolt - brake caliper front Allan head screw - brake pads rear Flat head bolt - brake discs Hexagon nut - front wheel spindle Hexagon nut - rear wheel spindle Hexagon nut - swingarm bolt Clamping bolts - top triple clamp Clamping bolts - bottom triple clamp Bolt - handlebar clamp...

  • Page 37: Technical Specifications - Engine

    TECHNICAL SPECIFICATIONS - ENGINE ENGINE 85 SX/XC Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 84.93 ccm Bore/stroke 47 / 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.

  • Page 38: Carburetor Setting

    CARBURETOR SETTING VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 28 MEERESHÖHE TEMPERATUR ALTITUDE TEMPERATURE 3000 m 10000 ft NADEL NEEDLE 2301 m 7501 ft 2300 m 7500 ft NADEL NEEDLE 1501 m 5001 ft 1500 m 5000 ft NADEL NEEDLE 751 m 2501 ft 750 m 2500 ft...

  • Page 39: Head Word Index

    Fuel tap ........7 General information about KTM disc brakes ..21 General tips and warnings for starting the motorcycle .10...
  • Page 42 *3211224en* 3211224en KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com...

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