KTM 85 SX 2013 Owner's manual
OWNER'S MANUAL 2013
85 SX 19/16
85 SX 17/14
Art. no. 3211856en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you and your child enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 10) Dealer's stamp
Engine number ( p. 10)
The owner's manual contained the latest information for this model at the time of going to print. Slight deviations resulting from continuing development and design can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 4
1.1 Symbols used ................................................... 4
1.2 Formats used.................................................... 4
2 SAFETY ADVICE........................................................... 5
2.1 Use definition - intended use ............................. 5
2.2 Safety advice.................................................... 5
2.3 Degrees of risk and symbols ............................... 5
2.4 Tampering warning............................................ 5
2.5 Safe operation .................................................. 5
2.6 Protective clothing ............................................ 6
2.7 Work rules........................................................ 6
2.8 Environment..................................................... 6
2.9 Owner's Manual ................................................ 6
3 IMPORTANT NOTES..................................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Service ............................................................ 7
3.5 Figures ............................................................ 7
3.6 Customer service............................................... 7
4 VIEW OF VEHICLE ....................................................... 8
4.1 View of vehicle, front left (example) .................... 8
4.2 View of vehicle, rear right (example) ................... 9
5 SERIAL NUMBERS .................................................... 10
5.1 Chassis number .............................................. 10
5.2 Type label ...................................................... 10
5.3 Engine number ............................................... 10
5.4 Fork part number ............................................ 10
5.5 Shock absorber part number ............................ 10
6 CONTROLS................................................................ 11
6.1 Clutch lever.................................................... 11
6.2 Hand brake lever............................................. 11
6.3 Throttle grip ................................................... 11
6.4 Kill switch...................................................... 11
6.5 Opening the filler cap...................................... 11
6.6 Closing the filler cap ....................................... 12
6.7 Fuel tap ......................................................... 12
6.8 Choke ............................................................ 13
6.9 Shift lever ...................................................... 13
6.10 Kick starter .................................................... 13
6.11 Foot brake lever .............................................. 13
6.12 Plug-in stand .................................................. 14
7 PREPARING FOR USE................................................ 15
7.1 Advice on first use .......................................... 15
7.2 Running in the engine ..................................... 16
7.3 Preparing the vehicle for difficult riding
conditions ...................................................... 16
7.4 Preparing for rides on dry sand......................... 17
7.5 Preparing for rides on wet sand ........................ 17
7.6 Preparing for rides on wet and muddy
surfaces ......................................................... 18
7.7 Preparing for rides at high temperature and
slow speed ..................................................... 18
7.8 Preparing for riding at low temperatures or in
snow.............................................................. 19
8 RIDING INSTRUCTIONS............................................. 20
8.1 Checks and maintenance work when preparing
for use ........................................................... 20
8.2 Starting.......................................................... 20
8.3 Starting off..................................................... 21
8.4 Shifting, riding ............................................... 21
8.5 Applying the brakes......................................... 21
8.6 Stopping, parking............................................ 22
8.7 Transport ....................................................... 22
8.8 Refueling ....................................................... 23
9 SERVICE SCHEDULE ................................................. 24
9.1 Service schedule............................................. 24
9.2 Service work (as additional order) ..................... 25
10 TUNING THE CHASSIS .............................................. 26
10.1 Checking the basic chassis setting with the
rider's weight.................................................. 26
10.2 Compression damping of the shock absorber...... 26
10.3 Adjusting the low-speed compression damping
of the shock absorber ...................................... 26
10.4 Adjusting the high-speed compression
damping of the shock absorber ......................... 27
10.5 Adjusting the rebound damping of the shock
absorber......................................................... 27
10.6 Measuring rear wheel sag unloaded................... 28
10.7 Checking the static sag of the shock absorber.... 28
10.8 Checking the riding sag of the shock absorber.... 28
10.9 Adjusting the spring preload of the shock
absorber x.................................................... 29
10.10 Adjusting the riding sag x .............................. 29
10.11 Checking the basic setting of the fork ............... 30
10.12 Adjusting the compression damping of the
fork ............................................................... 30
10.13 Adjusting the rebound damping of the fork ........ 30
10.14 Handlebar position.......................................... 31
10.15 Adjusting the handlebar position x ................. 31
11 SERVICE WORK ON THE CHASSIS.............................. 32
11.1 Raising the motorcycle with the lift stand .......... 32
11.2 Removing the motorcycle from the lift stand ...... 32
11.3 Bleeding the fork legs...................................... 32
11.4 Cleaning the dust boots of the fork legs............. 33
11.5 Removing the fork protector x ........................ 33
11.6 Installing the fork protector x......................... 33
11.7 Removing the fork legs x ............................... 34
11.8 Installing the fork legs x ................................ 34
11.9 Removing the lower triple clamp x.................. 35
11.10 Installing the lower triple clamp x .................. 36
11.11 Checking the play of the steering head
bearing .......................................................... 38
11.12 Adjusting the play of the steering head
bearing x ..................................................... 38
11.13 Greasing the steering head bearing x .............. 39
11.14 Removing the start number plate ...................... 39
11.15 Installing the start number plate....................... 39
11.16 Removing the front fender ............................... 39
11.17 Installing the front fender ................................ 39
11.18 Removing the shock absorber x ...................... 40
11.19 Installing the shock absorber x....................... 40
11.20 Removing the seat .......................................... 40
11.21 Mounting the seat ........................................... 40
11.22 Removing the air filter box lid .......................... 41
11.23 Installing the air filter box lid ........................... 41
11.24 Removing the air filter x ................................ 41
11.25 Installing the air filter x................................. 42
11.26 Cleaning the air filter and air filter box x ......... 42
11.27 Sealing the air filter box x.............................. 43
11.28 Removing the main silencer ............................. 43
11.29 Installing the main silencer.............................. 43
11.30 Changing the glass fiber yarn filling of the
main silencer x............................................. 43
TABLE OF CONTENTS 3
11.31 Removing the fuel tank x............................... 44
11.32 Installing the fuel tank x................................ 45
11.33 Checking for chain dirt accumulation ................ 45
11.34 Cleaning the chain .......................................... 45
11.35 Checking the chain tension .............................. 46
11.36 Adjusting the chain tension.............................. 46
11.37 Checking the chain, rear sprocket, engine
sprocket, and chain guide ................................ 47
11.38 Adjusting the chain guide x ........................... 49
11.39 Checking the frame x .................................... 49
11.40 Checking the swingarm x............................... 49
11.41 Checking the routing of the throttle cable.......... 49
11.42 Checking the rubber grip ................................. 50
11.43 Additionally securing the rubber grip................. 50
11.44 Adjusting the basic position of the clutch
lever .............................................................. 50
11.45 Checking the fluid level of the hydraulic
clutch............................................................ 50
11.46 Correcting the fluid level of the hydraulic
clutch............................................................ 51
11.47 Changing the hydraulic clutch fluid x.............. 51
12 BRAKE SYSTEM ........................................................ 52
12.1 Checking the free travel of the hand brake
lever .............................................................. 52
12.2 Adjusting the free travel of the handbrake
lever .............................................................. 52
12.3 Checking the brake discs ................................. 52
12.4 Checking front brake fluid level ........................ 53
12.5 Adding front brake fluid x.............................. 53
12.6 Checking the front brake linings ....................... 54
12.7 Changing the front brake linings x .................. 54
12.8 Checking the free travel of foot brake lever ........ 56
12.9 Adjusting the basic position of the foot brake
lever x ......................................................... 56
12.10 Checking the rear brake fluid level.................... 57
12.11 Adding rear brake fluid x ............................... 57
12.12 Checking the rear brake linings ........................ 58
12.13 Changing the rear brake linings x ................... 59
13 WHEELS, TIRES ........................................................ 61
13.1 Removing the front wheel x ........................... 61
13.2 Installing the front wheel x ............................ 61
13.3 Removing the rear wheel x............................. 62
13.4 Installing the rear wheel x.............................. 62
13.5 Checking the tire condition .............................. 63
13.6 Checking the tire air pressure........................... 64
13.7 Checking the spoke tension.............................. 64
14 COOLING SYSTEM ..................................................... 65
14.1 Cooling system ............................................... 65
14.2 Checking the antifreeze and coolant level .......... 65
14.3 Checking the coolant level ............................... 65
14.4 Draining the coolant x................................... 66
14.5 Refilling coolant x......................................... 66
15 TUNING THE ENGINE................................................ 68
15.1 Checking the play in the throttle cable .............. 68
15.2 Adjusting the play in the throttle cable x......... 68
15.3 Carburetor - idle.............................................. 68
15.4 Carburetor - adjusting idle speed x ................. 69
15.5 Emptying the carburetor float chamber x......... 70
15.6 Checking the basic position of the shift lever ..... 70
15.7 Adjusting the basic position of the shift
lever x ......................................................... 70
16 MAINTENANCE WORK ON THE ENGINE ..................... 72
16.1 Checking the gear oil level ............................... 72
16.2 Changing the gear oil x.................................. 72
16.3 Draining the gear oil x................................... 72
16.4 Filling up with gear oil x................................ 73
16.5 Adding gear oil x........................................... 73
17 CLEANING, CARE ...................................................... 75
17.1 Cleaning the motorcycle .................................. 75
18 STORAGE.................................................................. 76
18.1 Storage.......................................................... 76
18.2 Preparing for use after storage.......................... 76
19 TROUBLESHOOTING ................................................. 77
20 TECHNICAL DATA...................................................... 79
20.1 Engine........................................................... 79
20.2 Engine tightening torques ................................ 79
20.3 Capacities...................................................... 80
20.3.1 Gear oil...................................................... 80
20.3.2 Coolant...................................................... 80
20.3.3 Fuel .......................................................... 80
20.4 Chassis.......................................................... 80
20.5 Tires.............................................................. 81
20.6 Fork............................................................... 81
20.7 Shock absorber ............................................... 81
20.8 Chassis tightening torques ............................... 82
20.9 Carburetor...................................................... 83
20.9.1 Carburetor tuning........................................ 83
21 SUBSTANCES ........................................................... 85
22 AUXILIARY SUBSTANCES .......................................... 87
23 STANDARDS ............................................................. 89
INDEX .............................................................................. 90
1 MEANS OF REPRESENTATION 4
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
2 SAFETY ADVICE 5
2.1 Use definition - intended use
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
2 SAFETY ADVICE 6
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise
you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and
chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 8
4.1 View of vehicle, front left (example)
1 Hand brake lever ( p. 11)
2 Kill switch ( p. 11)
3 Clutch lever ( p. 11)
4 Air filter box lid
5 Fuel tap
6 Choke ( p. 13)
7 Shift lever ( p. 13)
8 Chain guide
L00009-10
4 VIEW OF VEHICLE 9
4.2 View of vehicle, rear right (example)
1 Filler cap
2 Throttle grip ( p. 11)
3 Fork rebound setting
4 Shock absorber rebound adjustment
5 Level viewer for brake fluid, rear
6 Shock absorber compression adjustment
7 Kick starter ( p. 13)
8 Foot brake lever ( p. 13)
9 Fork compression adjustment
L00019-10
5 SERIAL NUMBERS 10
5.1 Chassis number
Chassis number 1 is stamped on the right side of the steering head.
L00011-10
5.2 Type label
Type label 1 is located on the front frame tube.
5.3 Engine number
5.4 Fork part number
C00280-10
Engine number 1 is stamp into the engine case below the carburetor.
L00012-10
Fork part number 1 is stamped on the inner side of the axle clamp.
L00050-10
5.5 Shock absorber part number
L00013-10
Shock absorber part number 1 is stamped on the top of the shock absorber above the
adjusting ring on the engine side.
6 CONTROLS 11
6.1 Clutch lever
Clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
L00016-10
6.2 Hand brake lever
Hand brake lever 1 is located on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3 Throttle grip
6.4 Kill switch
L00017-10
Throttle grip 1 is fitted on the right side of the handlebar.
L00017-11
Kill switch 1 is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
L00016-11
6.5 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
6 CONTROLS 12
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Turn filler cap 1 counterclockwise and lift it off.
L00023-10
6.6 Closing the filler cap
L00023-11
6.7 Fuel tap
– Mount filler cap and turn it clockwise until the fuel tank is tightly closed.
Info
Run fuel tank breather hose 1 without kinks.
The fuel tap is on the left of the fuel tank.
Tap handle 1 on the fuel tap can be used to open or close the fuel supply to the carburetor.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel
tank empties fully.
L00035-10
6 CONTROLS 13
6.8 Choke
Choke lever 1 is fitted on the left side of the carburetor.
Activating the choke function frees an opening in the carburetor through which the
engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a
cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
L00020-10
6.9 Shift lever
• Choke function activated – The choke lever is pushed down all the way.
• Choke function deactivated – The choke lever is pushed up all the way.
Shift lever 1 is mounted on the left side of the engine.
6.10 Kick starter
L00024-10
The gear positions can be seen in the photograph.
The neutral or idle position N is between the first and second gears.
L00024-11
Kick starter 1 is fitted on the right side of the engine.
The kick starter can be swiveled.
Info
Before riding, swing the kickstarter inwards towards the engine.
L00025-10
6.11 Foot brake lever
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
L00026-10
6 CONTROLS 14
6.12 Plug-in stand
The fixture for plug-in stand 1 is located on the frame on the left side of the vehicle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
L00022-10
7 PREPARING FOR USE 15
7.1 Advice on first use
Warning
Danger of accidents Physical and mental readiness of a child.
– Your child must be able to ride a bicycle and must be able to erect the vehicle independently after a fall. In addition, your
child must understand the regulations and instructions from you or from other guardians. Do not ask too much of your
child; participation in competitive activities should not be considered until your child's stamina, riding techniques and
motivation are at the necessary levels. Children often underestimate or fail to recognize dangerous situations; make it clear
to your child that it should not, under any circumstances, operate the vehicle without supervision and that your child may
only drive at speeds that are commensurate with the child's riding abilities and the road conditions.
– Only let your child ride on the vehicle if it is physically and mentally ready to operate the vehicle.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. You and
your child should always used protective clothing that is in good condition and meets the legal requirements. When you
ride a motorcycle, set an example for your child and wear suitable protective clothing.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Brake system failure.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating.
Ensure that your child raises his or her foot from the foot brake lever when the child does not want to brake.
Warning
Danger of accidents Destruction of chassis components.
– Do not exceed the maximum allowable rider weight.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Carefully read the entire owner's manual together with your child before going for the first ride.
Info
Pay special attention to the safety warnings and injury risks.
Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence handling characteristics.
– Familiarize your child with the controls.
– Adjust the basic position of the clutch lever. ( p. 50)
– Adjust the free travel of the handbrake lever. ( p. 52)
–
Adjust the basic position of the foot brake lever. x ( p. 56)
– Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of your child.
7 PREPARING FOR USE 16
– Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large open meadow.
Info
To give your child a feel for the brake system, you should push your child at first. Do not start the engine until your child is
able to apply the necessary front brake pressure.
Initially, let your child drive to another person who can help your child stop and turn.
– Erect obstacles for your child to navigate around to accustom your child to handling the vehicle.
– Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not let your child ride on terrain that exceed your child's capabilities and experience.
– Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.
– Do not exceed the maximum allowable rider weight.
Guideline
Maximum rider weight 75 kg (165 lb.)
– Check the spoke tension. ( p. 64)
Info
The spoke tension must be checked after riding the motorcycle for half an hour.
– Run the engine in. ( p. 16)
7.2 Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
7.3 Preparing the vehicle for difficult riding conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more
rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
–
Seal the air filter box. x ( p. 43)
–
Clean the air filter and air filter box. x ( p. 42)
Info
Check the air filter approx. every 30 minutes.
– Additionally secure the rubber grip. ( p. 50)
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult riding conditions are:
– Rides on dry sand. ( p. 17)
– Rides on wet sand. ( p. 17)
– Rides on wet and muddy surfaces. ( p. 18)
– Rides at high temperature and slow speed. ( p. 18)
– Rides at low temperatures or in snow. ( p. 19)
7 PREPARING FOR USE 17
7.4 Preparing for rides on dry sand
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
L00021-10
– Change the radiator cap.
– Fit a dust cover on the air filter.
Dust protection device for air filter (59006019000)
Info
See the KTM PowerParts fitting instructions.
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
B00435-01
B00436-01
600868-01
7.5 Preparing for rides on wet sand
– Fit a sand cover on the air filter.
Sand protection device for air filter (59006022000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and the setting.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
– Clean the chain.
Chain cleaner ( p. 87)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 10 operating hours.
– Check the radiator cap.
L00021-10
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
7 PREPARING FOR USE 18
– Change the radiator cap.
– Fit a rain cover on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and the setting.
B00437-01
– Clean the chain.
– Fit the steel sprocket.
Your authorized KTM workshop can recommend the right carburetor tuning.
Chain cleaner ( p. 87)
Tip
Info
Do not grease the chain.
– Clean the radiator fins.
600868-01
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 10 operating hours.
7.6 Preparing for rides on wet and muddy surfaces
– Fit a rain cover on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and the setting.
B00437-01
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 75)
– Straighten bent radiator fins carefully.
600868-01
7.7 Preparing for rides at high temperature and slow speed
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
L00021-10
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
7 PREPARING FOR USE 19
– Change the radiator cap.
– Adjust the secondary drive to the road conditions.
Info
The engine oil heats up quickly when the clutch is operated frequently due
to an excessively high secondary drive.
– Clean the chain.
Chain cleaner ( p. 87)
600868-01
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 65)
7.8 Preparing for riding at low temperatures or in snow
– Fit a rain cover on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and the setting.
B00437-01
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
8 RIDING INSTRUCTIONS 20
8.1 Checks and maintenance work when preparing for use
Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.
– Check the gear oil level. ( p. 72)
– Check the front brake fluid level. ( p. 53)
– Check the rear brake fluid level. ( p. 57)
– Check the front brake linings. ( p. 54)
– Check the rear brake linings. ( p. 58)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 65)
– Check for chain dirt accumulation. ( p. 45)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 47)
– Check the chain tension. ( p. 46)
– Check the tire condition. ( p. 63)
– Check the tire air pressure. ( p. 64)
– Check the spoke tension. ( p. 64)
– Clean the dust boots of the fork legs. ( p. 33)
– Bleed the fork legs. ( p. 32)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel supply.
8.2 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Engine has been out of use for more than 1 week
–
Empty the carburetor float chamber. x ( p. 70)
– Turn tap handle 1 on the fuel tap to the ON position. (Figure L00035-10 p. 12)
Fuel can flow from the fuel tank to the carburetor.
– Remove the motorcycle from the stand.
– Shift gear to neutral.
The engine is cold
– Push the choke lever down all the way.
– Forcefully step on the kickstarter, pushing it all the way down.
Info
Do not open the throttle.
8 RIDING INSTRUCTIONS 21
8.3 Starting off
Info
The plug-in stand must be removed before riding.
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
– When conditions allow (incline, road situation, etc.), your child can shift into a higher gear. To do so, release the throttle while
simultaneously pulling the clutch lever, shift into the next gear, release the clutch, and open the throttle.
– If the choke function was activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the
speed but fuel consumption will be considerably lower.
– Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle increases fuel
consumption.
– To shift down, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and open the throttle or shift again.
– Your child should switch off the engine if he or she expects to be standing for a long time.
Guideline
≥ 2 min
– Your child should avoid frequent and extended slipping of the clutch. This heats the engine oil, the engine, and the cooling sys-
tem.
– Insist that your child ride with a low rpm instead of with a high rpm and a slipping clutch.
8.5 Applying the brakes
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
– Clean or dry a dirty or wet brake system by riding and braking gently.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Your child should change down to a lower gear appropriate to the
road speed.
– Insist that your child take advantage of the braking action of the engine when riding on long downhills. To do so, shift back one
or two gears, but do not overrev the engine. Your child will need to apply the brakes far less often and the brake system will not
overheat.
8 RIDING INSTRUCTIONS 22
8.6 Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side
stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
– Brake the motorcycle.
– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Turn tap handle 1 on the fuel tap to the OFF position. (Figure L00035-10 p. 12)
– Park the motorcycle on firm ground.
8.7 Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.
401475-01
8 RIDING INSTRUCTIONS 23
AA
8.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Switch off the engine.
– Open the filler cap. ( p. 11)
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 35 mm (1.38 in)
401522-10
Fuel tank capacity, approx.
2-stroke engine oil ( p. 85)
– Close the filler cap. ( p. 12)
5.0 l
(1.32 US gal)
Super unleaded gasoline (98 octane),
mixed with 2-stroke engine oil (1:40)
( p. 86)
9 SERVICE SCHEDULE 24
9.1 Service schedule
S10A S10N S20A S40A
Change the gear oil. x ( p. 72)
Check the front brake linings. ( p. 54) • • •
Check the rear brake linings. ( p. 58) • • •
Check the brake discs. ( p. 52) • • •
Check the brake lines for damage and leakage. • • •
Change the foot brake cylinder seals. x
Check the rear brake fluid level. ( p. 57) • • •
Check the free travel of the foot brake lever. ( p. 56) • • •
Check the frame and swingarm. x
Check the swingarm bearing. x
Check the heim joints at the top and bottom of the shock absorber. x
Perform a fork service. x
Perform a shock absorber service. x
Check the tire condition. ( p. 63) • • •
Check the tire air pressure. ( p. 64) • • •
Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x
Check the spoke tension. ( p. 64) • • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 47) • • •
Check the chain tension. ( p. 46) • • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x
Check the fluid level of the hydraulic clutch. ( p. 50) • • •
Check the front brake fluid level. ( p. 53) • • •
Check the free travel of the hand brake lever. ( p. 52) • • •
Check the play of the steering head bearing. ( p. 38) • • •
Change pistons and check cylinders. x
Change pistons and check cylinders. (in difficult operating conditions) x
Change the connecting rod, conrod bearing, and crank pin. x
Change the crankshaft bearing. x
Check the transmission and shift mechanism. x
Change the spark plug. x
Change the spark plug connector. x
Check the intake membrane. x
Check the exhaust control for functioning and smooth operation. x
Check the clutch. x
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and
incorrect routing. x
Check the antifreeze and coolant level. ( p. 65) • • •
Check the cables for damage and routing without sharp bends. x
Check that the cables are undamaged, routed without sharp bends and set correctly. • •
Clean the air filter and air filter box. x
Change the glass fiber yarn filling of the main silencer. x ( p. 43)
Check the screws and nuts for tightness. x
Check idle. x
Final check: Check the vehicle for safe operation and take a test ride. • • •
Make the service entry in KTM DEALER.NET and in the service record. x
• • •
• • •
• •
• •
• •
• •
•
•
• •
• •
• • •
• • •
• •
•
•
•
• •
•
• •
• •
• •
• • •
• • •
• • •
•
• • •
• • •
• • •
S10A: Every 10 operating hours
S10N: Once after 10 operating hours
S20A: Every 20 operating hours/after every race
9 SERVICE SCHEDULE 25
S40A: Every 40 operating hours
9.2 Service work (as additional order)
S40A S80A J1A
Change the front brake fluid. x
Change the rear brake fluid. x
Change the hydraulic clutch fluid. x ( p. 51)
Grease the steering head bearing. x ( p. 39)
Check/set the carburetor components. x
Change all engine bearings. x
S40A: Every 40 operating hours
S80A: Every 80 operating hours
J1A: Annually
• • •
•
•
•
•
•
10 TUNING THE CHASSIS 26
10.1 Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for an average rider's weight
(with full protective clothing).
Guideline
Standard rider weight 45… 55 kg (99… 121 lb.)
– If the rider's weight is above or below this range, the basic setting of the suspen-
sion components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
401030-01
10.2 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more
slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
10.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible
click.
L00028-10
Info
Do not loosen fitting 2.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
10 TUNING THE CHASSIS 27
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2.
– Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
L00027-10
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.5 Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
– Turn adjusting screw 1 clockwise up to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
L00029-10
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
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