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

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

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

7.3Preparing 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

7.6Preparing for rides on wet and muddy

surfaces .........................................................

18

7.7Preparing for rides at high temperature and

slow speed .....................................................

18

7.8Preparing for riding at low temperatures or in

snow..............................................................	19
8 RIDING INSTRUCTIONS.............................................	20

8.1Checks 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

10.1Checking the basic chassis setting with the

rider's weight..................................................	26
10.2 Compression damping of the shock absorber......	26

10.3Adjusting the low-speed compression damping

of the shock absorber ......................................

26

10.4Adjusting the high-speed compression

damping of the shock absorber.........................

27

10.5Adjusting 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
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

12.1Checking the free travel of the hand brake

lever ..............................................................

52

12.2Adjusting 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

			3
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

1.1Symbols 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).

1.2Formats used

The typographical formats used in this document are explained below.

Specific name	Identifies a proprietary name.
Name®	Identifies a protected name.
Brand™	Identifies a brand available on the open market.

2

SAFETY ADVICE

5

2.1Use 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.

2.2Safety 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.

2.3Degrees 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.

2.4Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1The 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

2the 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:

1Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.

2Removal or puncturing of any part of the intake system.

3Lack of proper maintenance.

4Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

2.5Safe 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.

2.6Protective 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.

2.7Work 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.

2.8Environment

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.

2.9Owner'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

3.1Guarantee, 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.

3.2Operating 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.

3.3Spare 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

3.4Service

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.

3.5Figures

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.

3.6Customer 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

4.1View of vehicle, front left (example)

L00009-10

1Hand brake lever ( p. 11)

2Kill switch ( p. 11)

3Clutch lever ( p. 11)

4Air filter box lid

5Fuel tap

6Choke ( p. 13)

7Shift lever ( p. 13)

8Chain guide

4

VIEW OF VEHICLE

9

4.2View of vehicle, rear right (example)

L00019-10

1Filler cap

2Throttle grip ( p. 11)

3Fork rebound setting

4Shock absorber rebound adjustment

5Level viewer for brake fluid, rear

6Shock absorber compression adjustment

7Kick starter ( p. 13)

8Foot brake lever ( p. 13)

9Fork compression adjustment

5

SERIAL NUMBERS

10

5.1Chassis number

Chassis number 1 is stamped on the right side of the steering head.

L00011-10

5.2Type label

Type label 1 is located on the front frame tube.

C00280-10

5.3Engine number

Engine number 1 is stamp into the engine case below the carburetor.

L00012-10

5.4Fork part number

Fork part number 1 is stamped on the inner side of the axle clamp.

L00050-10

5.5Shock absorber part number

Shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.

L00013-10

6

CONTROLS

11

6.1Clutch lever

Clutch lever 1 is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

L00016-10

6.2Hand 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.

L00017-10

6.3Throttle grip

Throttle grip 1 is fitted on the right side of the handlebar.

L00017-11

6.4Kill switch

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

6.5Opening 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 immediately 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

6.6Closing the filler cap

–Mount filler cap and turn it clockwise until the fuel tank is tightly closed.

Info

Run fuel tank breather hose 1 without kinks.

L00023-11

6.7Fuel tap

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

					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
					• Choke function activated – The choke lever is pushed down all the way.
			L00020-10
					• Choke function deactivated – The choke lever is pushed up all the way.
6		CONTROLS			Shift lever 1 is mounted on the left side of the engine.
				13
6.8		Choke
6.9		Shift lever
			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
6.10		Kick starter
					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

6.12Plug-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

7.1Advice 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)

7.2Running 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!

7.3Preparing 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

7.4Preparing 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
				system components when the engine is hot. Allow the engine
	L00021-10
				and cooling system to cool down. In case of scalding, rinse
				immediately with lukewarm water.

–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.

B00435-01

–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.
	B00436-01	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.
	600868-01

–If used in sand regularly, replace the piston every 10 operating hours.

7.5Preparing for rides on wet 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
					system components when the engine is hot. Allow the engine
	L00021-10
					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	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.
	600868-01

–If used in sand regularly, replace the piston every 10 operating hours.

7.6Preparing 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

7.7Preparing 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
					system components when the engine is hot. Allow the engine
	L00021-10
					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)
			– Clean the radiator fins.
	600868-01
			– 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

8.1Checks 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.

8.2Starting

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

8.3Starting 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.

8.4Shifting, 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 system.

–Insist that your child ride with a low rpm instead of with a high rpm and a slipping clutch.

8.5Applying 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

8.6Stopping, 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.

8.7Transport

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

8.8Refueling

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 immediately 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.
A	Guideline
	Measurement of A		35 mm (1.38 in)
	Fuel tank capac-	5.0 l	Super unleaded gasoline (98 octane),
	ity, approx.	(1.32 US gal)	mixed with 2-stroke engine oil (1:40)
			(	p. 86)
	2-stroke engine oil (	p. 85)
401522-10	– Close the filler cap. (	p. 12)

9

SERVICE SCHEDULE

24

9.1Service 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

Change the front brake fluid. x

Change the rear brake fluid. x

9 SERVICE SCHEDULE

S40A: Every 40 operating hours

9.2Service work (as additional order)

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

25

S40A	S80A	J1A
		•
		•
		•
		•
•	•	•
	•

10 TUNING THE CHASSIS

26

10.1Checking 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.

401030-01

–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 suspension 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.

10.2Compression 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.

10.3Adjusting 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.
						Info
						Do not loosen fitting 2.
		– Turn back counterclockwise by the number of clicks corresponding to the shock
			absorber type.
			Guideline
	L00028-10		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.

10.4Adjusting 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.

10.5Adjusting 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
Sport	12 clicks

L00029-10

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.