KTM 85 SX 2005 Owner'S Manual Download

Page: 21 / 40

ENGLISH

MAINTENANCE WORK ON CHASSIS AND ENGINE

0 mm

Checking chain tension

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.

Now, the distance between chain and swingarm should be 0 mm.

The upper part of the chain must be tight. Correct chain tension, if

necessary!

– IF THE CHAIN IS TOO TIGHT THE SECONDARY TRANSMISSION COMPONENTS

(CHAIN, SPROCKETS, BEARINGS OF THE TRANSMISSION AND OF THE REAR

WHEEL) WILL BE PUT UNDER ADDITIONAL STRAIN THAT CAN, IN ADDITION

TO PREMATURE WEAR, ALSO CAUSE CHAIN BREAKAGE.

– IF THE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND

BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN BOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE

MOTORCYCLE.

Correct chain tension

Loosen collar nut

[1]

, loosen lock nuts

[2]

, and turn right and left adjusting

screws

[3]

equally far. Tighten lock nuts.

Before tightening the collar nut, verify that the chain adjusters

[4]

are sitting

close to the adjusting screws and that the rear wheel has been aligned with

the front wheel.

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.

– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL

SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

NOTE:

The large adjusting range of the chain adjusters (32mm) allows you to use

different secondary ratios in combination with the same chain length. The

chain adjusters

[4]

can be rotated by 180°.

ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.

Chain maintenance

For long chain life, good maintenance is very important. The chain should be

cleaned in fireproof solvent regularly and afterwards treated with hot grease

or chain spray (Motorex Chainlube 622).

NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS,

OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS

WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE

CONTROL.

WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE

MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION.

Also check sprockets and chain guides for wear, and replace if necessary.

Summary of Contents for 85 SX 2005

Page 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 37 85 SX BEDIENUNGSANLEITUNG2005 ...

Page 2: ... illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2004 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only Please read this manual thoroughly before letting your youngster ride the motorcycle fo...

Page 3: ...iability for other products or consequential damage resulting 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 working order and only used on sa...

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 specifica tions 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 co...

Page 5: ...imself 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 super vising adult must be followed Your child must be physically ready to ride a motorcycle This means that he or she must at least be able t...

Page 6: ...ber and spring 18 Determining the static sag of the shock absorber 18 Determining the riding sag of the shock absorber 18 Overview of the shock absorber springs 19 Checking the basic setup of the telescopic fork 19 Overview of the telescopic fork springs 19 Checking chain tension 20 Correct chain tension 20 Chain maintenance 20 General information about KTM disc brakes 21 Adjusting free travel of ...

Page 7: ... lever 1 is located on the left side of the handlebar The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handle bars on the right and actu ates the front wheel brake The adjusting screw B is used t...

Page 8: ...e button 3 is located on the left side of the carburetor Pulling the choke button 3 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 lever is mounted on the left side of the engine The position ...

Page 9: ...m of the fork 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 05187A05 20 clicks Rebound damping of fork Hydraulic rebound damping determines t...

Page 10: ...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 15187A02 2 turns THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER U...

Page 11: ...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 rid ers are close To ensure that your youngster gets the feel of th...

Page 12: ...and 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 ...

Page 13: ...ly all the 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 ALWAYS REMOVE THE PLUG IN 3 STAND BEFORE YOUR CHILD RIDES THE MOTOR CYCLE ...

Page 14: ...fuel tap 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 AND GET BURNED CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURETOR MAY GET FLOODED AND FUEL ...

Page 15: ...ake system screws z z CHASSIS Check shock absorber and fork for leaks and function z z Clean dust bellows z Bleed fork legs z Check swing arm bearings z Check adjust steering head bearings z z Check tightness of all chassis screws triple clamps fork leg axle passageaxle nuts and screws swing arm bearings shock absorber z z WHEELS Check spoke tension and rim joint z z Check tires and air pressure z...

Page 16: ...xhaust systems with wax based anti corrosion agent z Check tightness of screws nuts and hose clamps regularly z RECOMMENDED INSPECTION OF THE 85 SX ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 30 hours 45 hours 60 hours 90 hours 120 hours 135 hours Check the reed type intake valve for wear z z z Check the clutch shoes for wear z z z z z z Check the...

Page 17: ...T 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 STRAPS OR OTHER MECHAN ICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREW...

Page 18: ... another The bores at the handlebar support 3 are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws 4 of the handlebar clamps and screws 5 of the handlebar support Position handlebar support and tighten screws 5 to 40 Nm Mount handlebar and handlebar clamps and tighten screws 4 to 20 Nm The gap between the handl...

Page 19: ...istance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dim...

Page 20: ...s If your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Overview of the telescopic fork springs 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...

Page 21: ...rews and that the rear wheel has been aligned with the front wheel 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 TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO...

Page 22: ...ENDS TO ABSORB WATER THEREFORE 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 thicknes...

Page 23: ...ONTAINER Checking front brake pads Inspect the brake pads from in front of the vehicle The linings must be at least 1 mm 0 04 in thick AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM 0 04 IN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR EN...

Page 24: ...WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC min 1 mm ...

Page 25: ...pull out the wheel spindle 6 Carefully remove the front wheel from the fork 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 ...

Page 26: ... THE REQUIRED TORQUE 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 y...

Page 27: ...lter support in the filter box making sure to center them and fix them prop erly 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 repla...

Page 28: ...the rubber bellows 4 At the slave cylinder of the clutch remove the bleeder nipple 5 In its place mount the bleeder syringe 6 which is filled with 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 proced...

Page 29: ...USE ONLY WITH HIGH GRADE ANTIFREEZE MOTOREX ANTI FREEZE USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORRO SION AND COOLANT FOAMING Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 3 a water temperature rising up to 120 C 248 F is admissible without fear of problems Checking coolant level The coolant should be 10 mm 0 4 in above the radiator fi...

Page 30: ...s after a short dis tance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one 1 2 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 6...

Page 31: ... FUEL PROPERLY Checking gear oil level Allow the engine 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 ad...

Page 32: ...n system Disconnect black coloured cable from short circuit button at ignition coil and check ignition spark If the spark is O K repair defec tive part of cable or ignition switch Inspect cable connectors Examine ignition system Dismantle and clean carburetor Engine without idle running Idle adjusting screw out of adjustment Ignition system damaged Wear Readjust idle running or replace idle adjust...

Page 33: ... examine tank aeration and clean Fit correct spark plug Check intake flange and carburettor if firmly setted Engine overheating Insufficient liquid in cooling system Radiator fins clogged Frothing in cooling system Pinched or kinked water hoses Incorrect ignition timing because of loose stator screws Incorrect compression ratio Top up coolant and bleed cooling system check cooling system for leaks...

Page 34: ...iods of time please 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 Rem...

Page 35: ...t max 70 kg Recommended age of rider 10 to 15 years Engine CR 85 STANDARD ADJUSTMENT FORK WP 4357 MXMA 05187A05 Compression adjuster 20 Rebound adjuster 20 Spring 3 N mm Spring preload 6 mm Air chamber length 100 mm Fork oil SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER WP 4618 PDS DCC WP 15187A02 Compression adjuster 17 LS LOW SPEED 2 HS HIGH SPEED Rebound adjuster 24 Spring 40 215 Spring preload 4 MM...

Page 36: ...1 compression ring Primary drive straight cut spur gears 19 66 t Clutch multiple disc clutch in oil bath hydraulic operated Motorex Kupplungs 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 engine oil Motorex Topspeed 4T 15W50 Ignition system Moric Digital 2M1 Spark plug NGK...

Page 37: ...l 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 M 6 8 Nm Spark plug M 14X1 25 20 Nm Reed valve housing M 14X1 5 100 Nm Kickstarter M 6 6 Nm Shift lever M 6 Loctite 243 12 Nm Swingarm pivot M 6 Loctite 243 12 Nm Other bolts M 5 M 6 6 Nm 10 Nm ...

Page 38: ... m 2501 ft LSO ASO LD IJ NADEL NEEDLE POS POS HD MJ 1 50 N5HF 3 122 1 25 48 N5HG 3 120 1 5 45 N5HG 2 118 1 75 42 N5HH 2 115 2 40 N5HH 2 115 750 m 2500 ft 301 m 1001 ft LSO ASO LD IJ NADEL NEEDLE POS POS HD MJ 0 75 50 N5HF 4 125 1 50 N5HF 3 122 1 25 48 N5HG 3 120 1 5 45 N5HG 3 118 1 75 42 N5HH 2 115 300 m 1000 ft Meeresniveau Sea level LSO ASO LD IJ NADEL NEEDLE POS POS HD MJ 0 5 50 N5HF 5 125 0 75...

Page 39: ... the static sag of the shock absorber 18 Dismounting and mounting the front wheel 24 Dismounting and mounting the rear wheel 25 Draining the float chamber of the carburetor 30 Driving instructions 11 Engine number 6 Page Exhaust system 26 Filler cap 7 Foot brake pedal 8 Fuel tap 7 General information about KTM disc brakes 21 General tips and warnings for starting the motorcycle 10 Hand brake lever...

Page 40: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 37 85 SX BEDIENUNGSANLEITUNG2005 ...

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