KTM 85 SX 2003 Owner's Manual
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KTM 85 SX 2003 Owner's Manual

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Summary of Contents for KTM 85 SX 2003

  • Page 2 Chassis number RAME NUMBER Engine number NGINE NUMBER Stamp of dealer TAMP OF DEA KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT...
  • Page 3 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.
  • Page 4 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 specifications must be used in accordance with the maintenance schedule.

  • Page 5: Driving

    IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING 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 maxi- mum weight of 75 kg (33,98 lb).

  • Page 6: Table Of Contents

    ......18 General information about KTM disc brakes ..19 OPERATION INSTRUMENTS .

  • Page 7: Serial Number Locations

    SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor.

  • Page 8: Filler Cap

    Filler cap 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 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.

  • Page 9: Kickstarter

    Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work). Plugin- Stand The plug-in stand included in the scope of supply can be plugged into...

  • Page 10: Damping Action During Compression Of Shock Absorber

    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.

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

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for the first ride WARNING – Verify that your KTM dealer performed the PREPARATION – H AVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER OF VEHICLE jobs (see Customer Service Manual).

  • 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

    Starting when the engine is cold 1 Open fuel tap 2 Put the gear in neutral 3 Activate the cold-starting aid (choke) 4 Leave throttle closed and kick down the kickstarter vigorously all the way. WARNING – T O AVOID INJURY WHEN STARTING THE ENGINE ALWAYS WEAR STRONG BIKERS BOOTS OU MAY SLIP OFF THE KICKSTARTER...

  • Page 14: Braking

    Refueling, fuel CAUTION Oil (high-grade two-stroke engine oil; i.e. Motorex Cross – D RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF Power 2T) must be mixed with the fuel (ROZ 95) at a mixing THE ENGINE E RECOMMEND TO WARM THE ENGINE UP AT A ratio of 1:40.

  • Page 15: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE 85 SX 1st service after after after 10 hours 20 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 1000 kilometers 2000 kilometers once a year Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs Check the carburetor connection boot for cracks and leaks...
  • Page 16 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear...

  • Page 17: Maintenance Work On Chassis And Engine

    WITH ASTERISK REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER WHERE YOUR MOTORCYCLE 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.

  • Page 18: Breather Plug Front Fork

    Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs 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.

  • Page 19: Changing The Spring Preloading Of The Shock Absorber

    Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring . 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.

  • Page 20: General Information About Ktm Disc Brakes

    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 continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 21: Checking Brake Fluid Level - Front Brake

    Checking brake fluid level - front brake The brake fluid reservoir is combined with the hand brake cylinder on the handlebars. To check the brake fluid level, the brake pistons must be pus- hed back to their basic position. The brake fluid level should be 5 mm below the upper edge of the reservoir (see illustration).

  • Page 22: Replacing The Front Brake Pades

    Replacing the front brake pades* 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 from the screw as well as fixing screw take the brake shoes out of the brake caliper.

  • Page 23: Checking The Rear Brake Fluid Level

    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 of the inspec- tion glass when the bike is in a horizontal position.

  • Page 24: Dismounting And Mounting The Front Wheel

    Remove the safety device , knock out the guide pin 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 .

  • Page 25: Dismounting And Mounting The Rear Wheel

    (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.

  • Page 26: Cleaning The Air Filter

    . 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. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING...

  • Page 27: Changing The Original Position Of The Clutch Lever

    . The oil level in the horizontal-positioned master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex Clutchfluid 75).Biodegradable hydraulic oil is available from your KTM dea- ler (50ml). CAUTION...

  • Page 28: Cooling System

    Cooling system The water pump in the engine keeps the cooling liquid in circulation. The cooling liquid is cooled by the air stream. Therefore, the cooling effect is reduced when the traveling speed is reduced. Dirty radiators additionally reduce the cooling effect. The cooling liquid can be drained by removing the screw on the water- pump cover.

  • Page 29: Carburetor Adjustment

    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 .

  • Page 30: Draining The Float Chamber Of The Carburetor

    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.

  • Page 31: 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 32 TROUBLE CAUSE REMEDY Engine has not enough Reed paddles tensionless or damaged, Replace reed paddles or reed valve housing power surface of reed valve housing damaged Wear Overhaul engine Engine revs not up and Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust running in four stroke too high, float needle seating is level...

  • Page 33: Cleaning

    CLEANING 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 EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 34: Technical Specifications - Chassis 85 Sx 2003

    TECHNICAL SPECIFICATIONS – CHASSIS 85 SX 2003 Frame Central chrome-moly-steel frame Fork telescopic fork White Power 43MXMA Wheel travel front/rear 275 mm (10.8 in) / 300 mm (11.8 in) Rear suspension WP PDS 4618 (Progressive Damping System) shock absorber Front brake Disc brake Ø...

  • Page 35: Technical Specifications - Engine 85 Sx 2003

    TECHNICAL SPECIFICATIONS - ENGINE 85 SX 2003 Engine CR-85 Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 84,926 ccm Bore/stroke 47 / 48.95 mm (1.85/1.93 in) Fuel SUPER fuel, research octane no 95, mixed with high grade two-stroke oil Oil/gasoline ratio 1:40 - 1:60 when using high grade two-stroke oil (e.g.
  • Page 36 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 10 Nm Nuts-cylinder base 30 Nm Flywheel collar nut M 12X1 60 Nm Hexagon nut for primary pinion M 10X1,25 Loctite 243 + 80 Nm Hexagon nut for clutch hub M 14X1,25 Loctite 243 + 60 Nm Crankcase and clutch cover bolts 8 Nm...
  • Page 37 Bleeding of the hydraulic clutch ....26 General information about KTM disc brakes ...19 Braking .
  • Page 38 321048...

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