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ENGLISH

21

MAINTENANCE WORK ON CHASSIS AND ENGINE

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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 RESERVOIRS:

The brake fluid reservoirs on front and rear wheel brakes have been

designed in such a way that even if the brake pads are worn it is not neces-

sary to top up the brake fluid. If the brake fluid level drops below the mini-

mum level either the brake system has a leak or the brake pads are completely

worn. In this case, consult an authorized KTM dealer immediately.

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 5.1 is a polyethylene glycol based fluid, amber-

colored and can be mixed with DOT 4 brake fluid.

Do not, in any event, use

DOT 5 brake fluid.

It is based on silicone oil and is dyed purple. KTM motor-

cycle gaskets and brake hoses are not designed for DOT 5 brake fluid.

Have the brake fluid changed at least once annually. If you wash your motor-

cycle often, the brake fluid should be changed even more frequently. Brake

fluid tends 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 thickness in a location B outside the contact

face. Check wear in several locations.

– Brake discs suffering from wear greater than 0.40 mm (0.016 in) consti-

tute a safety risk. Have the brake discs replaced immediately as soon as

they reach the wear limit.

– Have any repairs on the brake system be performed by a KTM dealer.

Adjusting free travel of the hand brake lever

Free travel of the hand brake lever may be readjusted by using the adjust-

ment screw

[2]

. In this way, the position of the point of pressure (i.e. the resist-

ance you feel on the hand brake lever when the brake pads are

pressed against the brake disc) can be adjusted for any hand size.

At the hand brake lever, free travel must at least be 3 mm (0.1 in). Only then

may the piston in the hand brake cylinder be moved (to be recognized by the

greater resistance of the hand brake lever). If this free travel is not provided,

pressure will build up in the braking system, and the front-wheel brake may

fail due to overheating.

A

B

1

min. 3 mm

2

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Содержание 85 SX

Страница 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm com KTM Group Partner 4 2007 FOTO MITTERBAUER 85 SX XC 105 SX XC OWNER S MANUAL 2008 3211224en 3211224en 3211224en ...

Страница 2: ...ertain 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 2007 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of...

Страница 3: ...r 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 avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The use of the motorcycle under extreme c...

Страница 4: ...rains 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 ON SAFE DRIVING FOR PARENTS on page 4 TRANSPORT When transporting your motorcycle secure it with elastic straps or other mechanical devices in an upright position Be sure that the fuel tap is closed...

Страница 5: ...ks 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 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 ab...

Страница 6: ...orber and spring 18 Page 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 tra...

Страница 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...

Страница 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 ...

Страница 9: ...screws at the bottom 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 Type WP Suspension 05187D05 15 clicks Type WP Suspension 05187D06 20 clicks Re...

Страница 10: ...e direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction Type WP Suspension 1518DC02 2 turns Type WP Suspension 15187D04 2 turns The damping unit of the shock absorber is filled with high compression nitro gen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could b...

Страница 11: ...er item 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 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 clo...

Страница 12: ...ent 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 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 le...

Страница 13: ...odern 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 drained from the float chamber The engine will start up immediately if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm 1 Open fuel tap 2 Put the gear in neutral 3 Leave throttle closed and kick down kickstarter vigorously ...

Страница 14: ...effect 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 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 t...

Страница 15: ...z z 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 for damage and leaks z z z Check adjust smooth operation and free travel of handbrake foot brake lever z z z Check the screws and guide bolts on the brake system for a tight fit z z z CHASSIS Check...

Страница 16: ...ontact grease z Change break fluid z z z Change hydraulic clutch fluid z Change the hydraulic clutch oil 85 105 SX XC 2008 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER OR THE MECHANIC before each start after every cleaning for cross country use once a year Check gear box oil level z Check brake fluid level z Check brake pads for wear z Lubricate and adjust cables and nipples z B...

Страница 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 straps or other mechanical 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 screws ...

Страница 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...

Страница 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...

Страница 20: ...our 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 45 kg or more than 55 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 bo...

Страница 21: ... 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 behavior of your motorcycle Tighten the collar nut with the required torque NOTE The large adjusting range of the chain adjusters 32mm allows you to use different secondary ratios in combination with the same chain length ...

Страница 22: ...id should be changed even more frequently Brake fluid tends 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 t...

Страница 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...

Страница 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 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 A Re...

Страница 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 ...

Страница 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 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 ...

Страница 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...

Страница 28: ...he 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 procedu...

Страница 29: ...se 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 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 fins...

Страница 30: ...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 68 F mainly...

Страница 31: ...ven 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 add 0 5 liters of gear oil e g Motorex Topspeed 4T 15W50 Mount the oil filler screw and check the engine for leaks If the gear oil is still clean you can continue to use it up to your next service too...

Страница 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 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 switch Inspect cable connect...

Страница 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...

Страница 34: ...riods 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 Re...

Страница 35: ...ng angle 66 Wheel base 1290 mm Seat height unloaded 865 mm 900 mm Ground clearance 385 mm 415 mm Dead weight without fuel 66 kg 68 kg Rider s body weight max 75 kg Recommended age of rider 10 to 15 years Engine CR 85 CR 105 STANDARD ADJUSTMENT FORK SX WP 4357 MXMA 05187D05 Compression adjuster 15 Rebound adjuster 20 Spring 3 4 N mm Air chamber length 110 mm Fork oil SAE 5 STANDARD ADJUSTMENT FORK ...

Страница 36: ... 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 5 75 Nm Clamping bolts top triple clamp M8 25 Nm Clamping bolts bottom triple clamp M8 15 Nm Bolt handlebar clamp M8 20 Nm Spoke nipple M4 5 5 Nm Other chassis bolts M6 M8 M10 10 Nm 25 Nm 45 Nm ...

Страница 37: ...spower 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...

Страница 38: ...751 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...

Страница 39: ...atic 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 Exhaust system 26 Page 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 6 How ...

Страница 40: ...ENGLISH 39 ...

Страница 41: ...ENGLISH 40 ...

Страница 42: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm com KTM Group Partner 4 2007 FOTO MITTERBAUER 85 SX XC 105 SX XC OWNER S MANUAL 2008 3211224en 3211224en 3211224en ...

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