OWNER’S MANUAL 2008 85 SX, XC 105 SX, XC *3211224en* 3211224en 3211224en 4/2007 FOTO: MITTERBAUER KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.
INTRODUCTION » Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you service and maintain it properly. Please insert the serial numbers of the motorcycle below ENGLISH Chassis number Engine number 1 Stamp of dealer All information contained is without obligation.
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 international motorcycle associations. ENGLISH 2 OWNER’S MANUAL Please read this manual thoroughly before letting your youngster ride the motorcycle for the first time.
IMPORTANT INFORMATION » WARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle. SPARE PARTS, ACCESSORIES For the safety of your child, only use spare parts and accessories approved by KTM.
IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING » ENGLISH The 85/105 SX/XC 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).
TABLE OF CONTENTS » Page Page IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE Determining the static sag of the shock absorber . . . .18 DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Determining the riding sag of the shock absorber . . . .18 Overview of the shock absorber springs . . . . . . . . . . .19 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .6 Checking the basic setup of the telescopic fork . . . . .19 Chassis number . . . . . . . . . . . . . . .
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 ENGLISH The engine number is stamped into the engine housing underneath the carburetor. Enter this number in the field on page no 1. 6 OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebar.
OPERATION INSTRUMENTS » Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 1 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. 2 ENGLISH Filler cap 7 OFF ON Fuel tap OFF ON In this position the fuel tap is closed. No fuel can flow to the carburetor.
OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal ENGLISH The foot brake pedal is located in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). 8 Plugin- Stand (SX) 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.
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. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for the first ride ENGLISH 10 – Make sure the work for the "pre-delivery inspection" was performed 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.
DRIVING INSTRUCTIONS » What you should check before each start 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. ENGLISH 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.
DRIVING INSTRUCTIONS » Starting when the engine is cold ENGLISH 1 2 3 4 1 12 Open fuel tap [1] . Put the gear in neutral Activate the cold-starting aid (choke) [2]. Leave throttle closed and kick down the kickstarter vigorously all the way. – To avoid injury when starting the engine, always wear strong bikers boots!You may slip off the kickstarter, or the engine may kick back if you do not kick hart enough.
DRIVING INSTRUCTIONS » – After falling with the motorcycle, check all its functions thoroughly before using it again. – A twisted handlebar must always be replaced. Do not adjust the handlebar, it will lose stability. – Driving a cold engine at 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.
z ENGINE CARBURETOR ADD-ON-PARTS BRAKES CHASSIS z z z z Check spark plugs, adjust distance between electrodes z Renew spark plugs z Clean the spark-plug connector and check for a tight fit z z z z Check the screws on the kick starter and shift lever for a tight fit z z z Check the carburetor connection boot and intake flange for cracks or leaks z Check idle speed setting z Check that vent hoses are not damaged or bent z z z z z z z z z Check cooling system for leaks, check qua
z Clean and adjust carburetor Check the reed-type intake valve for wear z z Check the wear on the clutch disks and length of the clutch springs z z Check the cylinder and piston for wear z z Check function of exhaust control z z Check piston pin bearing z Replace the crankshaft main bearings z Replace the conrod bearings z Check the entire transmission, the shift mechanism and bearings z Complete maintenance of fork z z z Complete maintenance of shock absorber z Clean and grease ste
MAINTENANCE WORK ON CHASSIS AND ENGINE » All maintenance and adjustment operations that are marked with an 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. ENGLISH – When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings, carburetor, electric connectors, etc.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lift the dust-protection bellows out of the outer tubes and slide them downward.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver A 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 45 and 55 kg (wearing full protective clothing).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Shock absorber 85/105 SX/XC SPRING RATE 40-215 35 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 standard spring is shown in bold print. After installing a different spring, readjust the static sag to 30-35 mm.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking chain tension 5-6 Support the motorcycle on the center stand or side stand, respectively. Switch transmission to neutral. Push the chain upwards from the end of the chain sliding component until the upper part of the chain is tensioned. The distance between the chain and the swing arm should be 5 - 6 cm. The lower part of the chain should be tightened.
MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: If the front brake caliper is removed, the screws must be secured with Loctite 243 when mounted and tightened to 25 Nm. BRAKE FLUID: We recommend that you use Motorex DOT 5.1 brake fluid when you refill or change the brake fluid. DOT 5. 1 brake fluid has a wet boiling point of 180°C / 356°F (25°C / 45°F higher than DOT 4) and is safer for high performance applications. Brake fluid DOT 5.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the brake fluid level/ refilling * 1 1 2 3 ENGLISH 5 mm 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1]. Using the push rod [2], the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Remove the safety device [1], knock out the guide pin [2] from the brake caliper with a drift towards the chain wheel and remove the brake pads. Carefully clean the brake caliper with compressed air and check the sleeves of the guide pins for damage. 2 1 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.lb).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Dismounting and mounting the rear wheel 2 1 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accumulated. 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. Do not clean the air filter with fuel or petroleum since these will damage the foam.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw counterclockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw clockwise increases the distance between the clutch lever and the handlebar.
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. 1 2 ENGLISH 3 28 The cooling liquid can be drained by removing the screw [2] on the waterpump cover. – If possible, always check level of cooling liquid when the engine is cold.
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 .
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. 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.
TROUBLE SHOOTING » TROUBLE Engine fails to start CAUSE Operating error REMEDY Open fuel tap, replenish fuel, do not use choke The motorcycle was not driven for a longer period of time, leaving old fuel in the float chamber 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 chamber.
TROUBLE SHOOTING » TROUBLE Engine has not enough power CAUSE REMEDY 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 seating is dirty or enlarged Loose carburetor jets High rpm misfiring Tighten jets Incorrect heat range spark plug Refe
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. – You should use commercially available detergents to clean the motorcycle. Heavily soiled parts should also be cleaned with the help of a paint brush.
TECHNICAL SPECIFICATIONS – CHASSIS » ENGLISH 34 CHASSIS 85 SX/XC (17”/14”) Frame Central chrome-moly-steel frame Fork telescopic fork WP Suspension 4357 MXMA Wheel travel front/rear 275 mm / 300 mm (10.82/11.81 in) Rear suspension WP PDS 4618 (Progressive Damping System) shock absorber Front brake Disc brake Ø 220 mm (8.66 in), 4 piston Rear brake Disc brake Ø 200 mm (7.
TECHNICAL SPECIFICATIONS - CHASSIS » Hexagon bolt - brake caliper front M8 Loctite 243 + 25 Nm Allan head screw - brake pads rear M6 5 Nm Flat head bolt - brake discs M6 14 Nm Hexagon nut - front wheel spindle M10x1.5 40 Nm Hexagon nut - rear wheel spindle M20x1.5 80 Nm Hexagon nut - swingarm bolt M14/M 16x1.
TECHNICAL SPECIFICATIONS - ENGINE » ENGLISH ENGINE 85 SX/XC Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 84.93 ccm 103.96 ccm Bore/stroke 47 / 48.95 mm 52 / 48.95 mm Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two-stroke oil Oil/gasoline ratio 1 : 40 - 1 : 60 when using high grade two-stroke oil (e.g.
CARBURETOR SETTING » VERGASERREGULIERUNG CARBURETOR SETTING 85/105 SX/XC 2008 KEIHIN PWK 28 3000 m 10000 ft 2301 m 7501 ft 2300 m 7500 ft 1501 m 5001 ft 1500 m 5000 ft 751 m 2501 ft 750 m 2500 ft 301 m 1001 ft 300 m 1000 ft Meeresniveau Sea level LSO LD POS HD = = = = TEMPERATUR TEMPERATURE - 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 -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F LSO LD NADEL POS HD ASO IJ NEEDLE POS MJ 1,5 45 N5HG 2 118 1,75 4
HEAD WORD INDEX » ENGLISH 38 Page Page Adjusting free travel of the hand brake lever . . . . . . .21 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Adjusting the throttle cable . . . . . . . . . . . . . . . . . . .27 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Basic suspension setup for the weight of the driver . . .18 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Bleeding of the hydraulic clutch . . . . .
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OWNER’S MANUAL 2008 85 SX, XC 105 SX, XC *3211224en* 3211224en 3211224en 4/2007 FOTO: MITTERBAUER KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.
