KTM 85 SX 2003 Owner'S Manual Download

Page: 6 / 38

ENGLISH

TABLE OF CONTENTS

Page

IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE

DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .6

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .6

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Plugin- Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Compression damping of fork . . . . . . . . . . . . . . . . . . . .8

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .8

Damping action during compression of shock absorber .9

Rebound damping function of the shock absorber . . . . .9

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Instructions for the first ride . . . . . . . . . . . . . . . . . . . . .10

Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .11

What you should check before each start . . . . . . . . . . .11

Starting when the engine is cold . . . . . . . . . . . . . . . . . .12

Starting when the engine is warm . . . . . . . . . . . . . . . .12

What to do when the engine is “flooded“ . . . . . . . . . .12

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .14

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .16

Checking and adjusting the steering head bearing . . . . .16

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . .17

Page

Cleaning the dust sleeves of the telescopic fork . . . . . .17

How to change the handlebar position . . . . . . . . . . . . .17

Changing the spring preloading of the shock absorber .18

Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . .18

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .18

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .18

General information about KTM disc brakes . . . . . . . . .19

Adjusting free travel of the hand brake lever . . . . . . . .19

Checking brake fluid level - front brake . . . . . . . . . . . .20

Refilling front brake fluid reservoir . . . . . . . . . . . . . . . . .20

Checking the front brake pads . . . . . . . . . . . . . . . . . . .20

Replacing the front brake pades . . . . . . . . . . . . . . . . . .21

Changing basic position of the brake pedal . . . . . . . . . .21

Checking the rear brake fluid level . . . . . . . . . . . . . . . .22

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .22

Checking rear brake pads . . . . . . . . . . . . . . . . . . . . . . .22

Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .22

Dismounting and mounting the front wheel . . . . . . . . .23

Dismounting and mounting the rear wheel . . . . . . . . .24

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .24

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Changing the original position of the clutch lever . . . . .26

Checking the oil level of the hydraulic clutch . . . . . . . .26

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .26

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Checking coolant level . . . . . . . . . . . . . . . . . . . . . . . . .27

Refilling/Bleeding the cooling system . . . . . . . . . . . . . .27

Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . . .27

Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .28

Draining the float chamber of the carburetor . . . . . . . .29

Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . .29

Changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

TECHNICAL SPECIFICATIONS – CHASSIS 85 SX 2003 . .33

TECHNICAL SPECIFICATIONS - ENGINE 85 SX 2003 . . .34

Summary of Contents for 85 SX 2003

Page 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art Nr 3 210 48 1 2003 85 SX ...

Page 2: ...NFORMATION MARKED AS FOLLOWS WARNING IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE S TRAFFIC SAFETY Chassis number Engine number Stamp of dealer KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND T...

Page 3: ... ting 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 wor king order and only used on safe terrains Nevertheless driving the motorcycle like dr...

Page 4: ...e 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 No claims can be filed under the warranty for damage or consequential damage caused by manipulations or con...

Page 5: ...r 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 supervising adult must be followed Your child must be physically ready to ride a motorcycle This means that ...

Page 6: ...ndlebar position 17 Changing the spring preloading of the shock absorber 18 Checking chain tension 18 Correct chain tension 18 Chain maintenance 18 General information about KTM disc brakes 19 Adjusting free travel of the hand brake lever 19 Checking brake fluid level front brake 20 Refilling front brake fluid reservoir 20 Checking the front brake pads 20 Replacing the front brake pades 21 Changin...

Page 7: ...e adju sting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine Hand brake lever The hand brake lever 2 is mounted on the handle bars on the right and actuates the front wheel brake The adjusting screw B is used to change the original position of the hand brake lever see maintenance work on chassis and engine Short circuit button The shor...

Page 8: ...ank will drain completely in this position Choke The choke button 2 is located on the left side of the carburetor Pulling the choke button 2 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 leve...

Page 9: ...rk 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 White Power 0518Y733 20 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction...

Page 10: ...e direction Typ White Power 1518Y703 17 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 Typ White Power 1518Y703 2 turns WARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY...

Page 11: ... 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 in the garden Be sure that there is room enough to maneuver and that no other riders are close To ensure that your youngster gets the fee...

Page 12: ...incorrect air pressure deteriorate the driving performance 5 BRAKES Check the correct functioning of the braking system Verify that there is 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 brak...

Page 13: ...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 Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time WARNING ALWAYS REMOVE THE PLUG IN 3 STAND BEFORE YOUR CHILD RIDES THE MOTORCYCLE Shif...

Page 14: ...ft gears to idling To switch off the engine depress short circuit switch until the engine stops Close fuel tap WARNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT 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 ...

Page 15: ...ric systems emergency OFF switch or button Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings ...

Page 16: ...ck tightness of screws nuts and hose clamps regularly For cross country use Once a year After every cleaning Before each start RECOMMENDED INSPECTION OF THE 85 SX ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP Check the reed type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston...

Page 17: ... 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 WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAP...

Page 18: ...s thoroughly and oil them thoroughly with silicone spray or engine oil Then push dust pro tection bellows into the outer tubes by hand WARNING NO SILICONE 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 c...

Page 19: ...GINE IN BOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 3 loosen lock nuts 4 and turn right and left adjusting screws 5 equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters 6 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nu...

Page 20: ...E 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...

Page 21: ... WARNING 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 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 I...

Page 22: ...ED CORRECTLY HAVING PERFORMED ANY WORK 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 PRESSURE POINT IS ESTABLISHED DO NOT UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL HAVE TO BLEED THE BRAKE SYSTEM Changing basic position of the brake pedal The basic settin...

Page 23: ...LLY ADAPTED TO IT 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 b...

Page 24: ...t 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 axl...

Page 25: ...E 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 you...

Page 26: ...g sure to center them and fix them properly 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 vehic...

Page 27: ...L 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 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 3together with th...

Page 28: ...N 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 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 l 0 06 US gallons cooling liquid Make sure that the drain screw 4 is fastened Pour approx 0 5 litres 0...

Page 29: ...fluenced by the posi tion of the air control screw 2 and the air control screw 3 Only make adjustments 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 turning the screw counterclockwise produces a lower idling speed Create a round and stable engine speed using the air contr...

Page 30: ...e to warm up park the motorcycle in a horizontal position jack up and wait for 3 5 minutes to allow the oil to flow back into the clutch housing To check the gear oil level remove the inspection window screw 2 Oil should just barely leak out at the inspection window when the bike is in a horizontal position If necessary remove the plug 4 and add oil see technical specifications engine e g Motorex ...

Page 31: ...uced at the spark plug If no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstarter If a spark now occurs replace spark plug cap If 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 swi...

Page 32: ...d water hoses Incorrect ignition timing because of loose stator screws Incorrect compression ratio Cylinder head or O ring of cylinder head gasket leaks Excessive oil quantity in transmis sion Shaft seal ring of the water pump defect REMEDY Replace reed paddles or reed valve housing Overhaul engine Clean carburetor if necessary replace float needle and adjust level Tighten jets Refer to technical ...

Page 33: ...se 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 an...

Page 34: ...commended age of rider 10 to 15 years Engine CR 85 TECHNICAL SPECIFICATIONS CHASSIS 85 SX 2003 Hexagon screw brake caliper M 8 Loctite 243 25 Nm Flat head screw brake discs M 6 Loctite 243 10 Nm Hexagon nut front wheel spindle M 10x1 5 30 Nm Hexagon nut rear wheel spindle M 20x1 5 80 Nm Hexagon nut swingarm bolt M 14 M 16x1 5 100 Nm Clamping screws upper fork bridge M 8 20 Nm Clamping screws lower...

Page 35: ...ars 19 66 t Clutch multiple disc clutch in oil bath hydraulic operated Motorex clutch fluid 75 Transmission 6 speed claw actuated Gear ratio 1st gear 11 29 2nd gear 14 28 3rd gear 16 26 4th gear 19 26 5th gear 21 25 6th gear 20 21 Transmission oil 0 35 liter 0 0924 USgal Motoröl Motorex Topspeed 4T 15W50 Ignition system Moric Digital 2M1 Spark plug NGK BR 10 ECMVX Electrode gap 0 60 mm 0 0236 in C...

Page 36: ...exagon 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 M 6 8 Nm Spark plug M 14X1 25 20 Nm Swingarm pivot M 14X1 5 100 Nm Membrane M 6 6 Nm Kickstarter M 6 Loctite 243 12 Nm Shift drum locating M 6 Loctite 243 12 Nm Other screws M 5 6 Nm M 6 10 Nm ...

Page 37: ...g the rear wheel 24 Draining the float chamber of the carburetor 29 Driving instructions 11 Engine number 6 Exhaust system 25 Filler cap 7 Page Foot brake pedal 8 Fuel tap 7 General information about KTM disc brakes 19 General tips and warnings for starting the motorcycle 10 Hand brake lever 6 How to change the handlebar position 17 Important information for parents about safe driving 4 Instructio...

Page 38: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321048 ...

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