Related Manuals for KTM 85 SX 2005
Summary of Contents for KTM 85 SX 2005
- Page 1 BEDIENUNGSANLEITUNG2005 85 SX OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.211.37...
- 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 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.
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Page 4: Important Warranty And Guarantee Information
» IMPORTANT WARRANTY AND GUARANTEE INFORMATION 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 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 maximum weight of 75 kg (33,98 lb). -
Page 6: Table Of Contents
Hand brake lever ......6 General information about KTM disc brakes ..21 Short circuit button . -
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: Short Circuit Button
» OPERATION INSTRUMENTS Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 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 [2] without kinks. -
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
» OPERATION INSTRUMENTS Damping action during compression of shock absorber The shock absorber on the models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. -
Page 11: General Tips And Warnings For Starting The Motorcycle
» GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for the first ride – Verify that your KTM dealer performed the PREPARATION OF – HAVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR VEHICLE jobs (see Customer Service Manual). WHENEVER HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE –... -
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
» DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open fuel tap [1] . 2 Put the gear in neutral 3 Activate the cold-starting aid (choke)[2]. 4 Leave throttle closed and kick down the kickstarter vigorously all the way. –... -
Page 14: Refueling, Fuel
MOTORCYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR CHILD SHOULD STOP IMMEDIATELY, TURN THE – ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE. -
Page 15: Periodic Maintenance Schedule
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service Intervals should never be exceeded by more than 5 hours or 500 km! Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider! - Page 16 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 RECOMMENDED INSPECTION OF THE 85 SX ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) hours...
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Page 17: Maintenance Work On Chassis And Engine
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 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
» MAINTENANCE WORK ON CHASSIS AND ENGINE 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. -
Page 20: Overview Of The Shock Absorber Springs
Front fork 85 SX 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. -
Page 21: Checking Chain Tension
Tighten collar nut [1] to 80 Nm (60 ft.lb). – 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. -
Page 22: 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. If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid. -
Page 23: Checking The Brake Fluid Level/ Refilling
» MAINTENANCE WORK ON CHASSIS AND ENGINE 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
» MAINTENANCE WORK ON CHASSIS AND ENGINE Changing basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1]. Using the push rod [2], the free play on the foot brake pedal must be set. -
Page 25: Dismounting And Mounting The Front Wheel
10Nm (7ft.lbs) – 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. -
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 BEHAV- IOR 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... -
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 Cooling system The water pump [1] in the engine keeps the cooling liquid in circulation. The cooling liquid is cooled by the air stream. Therefore, the cooling effect is reduced when the traveling speed is reduced. Dirty radiators additionally reduce the cooling effect. -
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 . -
Page 31: Draining The Float Chamber Of The Carburetor
» MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber leads to engine malfunction. Make sure you do this while the engine is cold. -
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 CAUSE REMEDY Engine has not enough power Reed paddles tensionless or Replace reed paddles or reed valve housing damaged, surface of reed valve housing damaged Wear Overhaul engine Engine revs not up and running Carburetor overflows if level Clean carburetor, if necessary replace float needle and adjust level in four stroke cycle adjust too high, float needle seat-...
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Page 34: 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. -
Page 35: Technical Specifications - Chassis
» TECHNICAL SPECIFICATIONS – CHASSIS Frame Central chrome-moly-steel frame Fork telescopic fork White Power 43 MXMA Wheel travel front/rear 275 mm / 300 mm Rear suspension WP PDS 4618 (Progressive Damping System) shock absorber Front brake Disc brake Ø 220 mm, 4 piston Rear brake Disc brake Ø... -
Page 36: Technical Specifications - Engine
» TECHNICAL SPECIFICATIONS - ENGINE Engine CR-85 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 37 » TECHNICAL SPECIFICATIONS - ENGINE TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 10 Nm Nuts-cylinder base 30 Nm Flywheel collar nut M 12X1 60 Nm Primary gear bolt M 10X1,25 Loctite 243 + 80 Nm Nut for inner clutch hub M 14X1,25 Loctite 243 + 60 Nm Crankcase and cover bolts...
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Page 38: Carburetor Setting
» CARBURETOR SETTING VERGASERREGULIERUNG 85 SX 2005 CARBURETOR SETTING KEIHIN PWK 28 MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C ALTIDUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F... -
Page 39: Head Word Index
Braking ....... . .13 General information about KTM disc brakes ..21 Breather plug front fork . - Page 40 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...