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TECHNICAL SPECIFICATIONS - ENGINE  85/105 SX  2007

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ENGINE

85 SX

105 SX

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. Motorex 2T Crosspower), 
when in doubt, please contact your importer

Lubrication

mixture lubrication

Crankshaft bearing

deep-groove ball bearing, cylinder roller bearing

Connecting rod bearing needle bearing
Piston pin bearing

needle bearing

Piston rings

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

1

st

gear   11 : 29

2

nd

gear   14 : 28

3

rd

gear   16 : 26

4

th

gear   19 : 26

5

th

gear   21 : 25

6

th

gear   20 : 21

Transmission oil

0.5 liter engine oil Motorex Topspeed 4T 15W50

Ignition system

Moric Digital 2M1

Spark plug

NGK BR 9 EVX

Electrode gap

0.60 mm

Carburetor

flat-slide carburetor, carburetor see table

Coolant

1 liter, mixture 50% antifreeze, 50% distilled water, at least –25° C (-13° F)

Air filter

wet foam type air filter insert

BASIC CARBURETOR SETTING

Carburetor

Keihin PWK 28

Main jet

118

Needle jet

2.6

Idling jet

45

Jet needle

N5HG

Needle position from top

III

Throttle valve

3.5

Starting jet

62

Air adjustment screw open

1,5

Summary of Contents for 85 SX 2007

Page 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 5 2006 FOTO MITTERBAUER 85 105 SX OWNER S MANUAL 2007 ART NR 3 211 143 EN ENGLISH...

Page 2: ...rtain 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...

Page 3: ...cycle is sold SERVICE Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoida...

Page 4: ...ains Nevertheless driving the motorcycle like driving any other vehicle involves a potential risk Therefore please make sure that all fundamental precautions are taken Please also read the INFORMATION...

Page 5: ...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...

Page 6: ...er 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 teles...

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 hydraul...

Page 8: ...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 th...

Page 9: ...f 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...

Page 10: ...mit 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 WP Suspension 15187C02 2 turns The da...

Page 11: ...em by item pay ing particular attention 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 ea...

Page 12: ...nt tread 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 re...

Page 13: ...w r p m speeds NOTE The highly inflammable components in modern fuels volatilize if left stand ing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be dra...

Page 14: ...ffect In extreme cases the entire braking system can fail Stopping Brake motorcycle and shift gears to idling To switch off the engine depress short circuit switch until the engine stops Close fuel ta...

Page 15: ...z z z Check electric wires for damage and bends z z Check function of electric systems emergency OFF switch z z z BRAKES Check brake fluid level lining thickness brake lining z z z Check brake lines f...

Page 16: ...ntact grease z Change break fluid z z z Change hydraulic clutch fluid z Change the hydraulic clutch oil 85 105 SX 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER OR THE MECHANIC b...

Page 17: ...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...

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 handl...

Page 19: ...stance 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 verti...

Page 20: ...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 I...

Page 21: ...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...

Page 22: ...nds 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 o...

Page 23: ...ntainer 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 t...

Page 24: ...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 l...

Page 25: ...ull 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...

Page 26: ...the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle 1 2 3 Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle r...

Page 27: ...ter 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...

Page 28: ...e 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...

Page 29: ...e only with high grade antifreeze Motorex Anti Freeze Using lower grade antifreeze agents can cause corrosion and coolant foaming Pressure induced by heating of the coolant in the system is controlled...

Page 30: ...arger 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 setti...

Page 31: ...en surface Remove the oil drain plug 2 and allow the gear oil to drain into a vessel Clean the sealing area mount the oil drain plug and gasket and tighten to 15 Nm Remove the oil filler screw 4 and a...

Page 32: ...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...

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 c...

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...

Page 35: ...without fuel 66 kg 68 kg Rider s body weight max 75 kg Recommended age of rider 10 to 15 years Engine CR 85 STANDARD ADJUSTMENT FORK WP 4357 MXMA 05187C05 Compression adjuster 20 Rebound adjuster 20 S...

Page 36: ...ring Piston rings 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 actua...

Page 37: ...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 M 6 8 Nm Spark plug M 14X1 25 20 Nm Reed v...

Page 38: ...1 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...

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 E...

Page 40: ...ENGLISH 39...

Page 41: ...ENGLISH 40...

Page 42: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 5 2006 FOTO MITTERBAUER 85 105 SX MANUAL DE INSTRUCCIONES 2007 ART NR 3 211 143 ES ESPA OL...

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